80D-7E Hyundai Shop Manual

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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-15
SECTION 2 REMOVAL AND INSTALLATION OF UNIT

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

Group 1 Structure and operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
Group 2 Operation and maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-30
Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-57
Group 4 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-156

Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-20
Group 3 Tests and adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-22
Group 4 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-24

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

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

Group 1 Component location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1
Group 2 Electrical circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2
Group 3 Component specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
Group 4 Connector destination - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-14
Group 5 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
SECTION 8 MAST
Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1
Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-8
Group 4 Removal and installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-10
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.
Â 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.
Â 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
Â Flames should never be used instead of

lamps. Never use a naked flame to check
leaks or the level of oil or electrolyte.
D50ASF03
Â 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.
Â 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
Â When working on top of the machine, be

careful not to lose your balance and fall.
D50ASF06
Â 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.
Â 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
Â When working with others, choose a group

leader and work according to his instructions.
Do not perform any maintenance beyond the
agreed work.
D50ASF10
Â 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.
D50ASF11
Â 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.
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.
Â Always use HYUNDAI Forklift genuine parts for replacement.
Â Always use the grades of grease and oil recommended by HYUNDAI Forklift.
Choose the viscosity specified for the ambient temperature.
Â Always use pure oil or grease, and be sure to use clean containers.
Â When checking or changing the oil, do it in a place free of dust, and prevent any dirt from getting into
the oil.
Â Before draining the oil, warm it up to a temperature of 30 to 40Á C.
Â After replacing oil, filter element or strainer, bleed the air from circuit.
Â When the strainer is located in the oil filler, the strainer must not be removed while adding oil.
Â When changing the oil filter, check the drained oil and filter for any signs of excessive metal particles
or other foreign materials.
Â When removing parts containing O-ring, gaskets or seals, clean the mounting surface and replace
with new sealing parts.
Â After injecting grease, always wipe off the oil grease that was forced out.
Â Do not handle electrical equipment while wearing wet places, as this can cause electric shock.
Â During maintenance, do not allow any unauthorized person to stand near the machine.
Â 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.
Â 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.
Â 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
9 8
15
1 10
2
12
3
11
4 13
14
50DEOM54
1 Mast 6 Forks 11 Bonnet

2 Lift chain 7 Overhead guard 12 Counterweight
3 Lift cylinder 8 Turn signal lamp 13 Rear wheel
4 Backrest 9 Head lamp 14 Front wheel
5 Tilt cylinder 10 Operator's seat 15 Rear combination lamp
1-5
2. SPECIFICATIONS
C C'
D
R
A
H
E
M'
M
I
W
B
F
J
L K
G
50DESP01
Model Unit 50D-7E 60D-7E 70D-7E 80D-7E

Capacity kg 5000 6000 7000 8000
Load center R mm 600 ą ą ą
Weight(Unloaded) kg 8440 9218 9839 11046
Lifting height A mm 3000 3030 3000 ą
Free lift B mm 140 ą ą 145
Fork Lifting speed(Unload/Load) mm/sec 460/440 460/430 450/400 480/420
Lowering speed(Unload/Load) mm/sec 450/500 ą ą ą
LÝWÝT L,W,T mm 1200Ý150Ý60 1200Ý180Ý60 ą 1200Ý180Ý70
Tilt angle (forward/backward) C/C’ degree 15/10 ą ą ą
Mast Max height D mm 4275 ą ą 4375
Min height E mm 2515 ą ą 2675
Travel speed km/h 35.1 34.9 33.6 34.5
Body Gradeability degree 20.6 18.1 18.8 18.2
Min turning radius(Outside) F mm 3270 3315 3270 3600
Max hydraulic pressure kgf/cm2 188 ą ą ą
ETC Hydraulic oil tank ˶ 133 ą ą 100
Fuel tank ˶ 165 ą ą 185
Overall length G mm 3500 3565 3670 3900
Overall width H mm 2087 ą ą 2277
Overhead guard height I mm 2500 ą ą 2603
Ground clearance J mm 190 195 ą 250
Wheel base K mm 2300 ą ą 2500
Wheel tread front/rear M, M' mm 1580/1604 ą ą 1632/1700
1-6
3. SPECIFICATION FOR MAJOR COMPONENTS
1) 50D/60D/70D-7E
(1) ENGINE
Item Unit Specification
Model HYUNDAI D4DD-C7

Type 4 cycle turbocharged diesel type
Cooling Method Water cooling
Number of cylinders and arrangement 4 cylinders, In-line
Firing order 1-3-4-2
Combustion chamber type Direct injection
Cylinder bore X stroke mm(in) 104Ý115(4.1Ý4.5)
Piston displacement cc(cu in) 3907(238)
Compression ratio 17.5 : 1
Rated gross horse power ps/rpm 100/2300
Maximum gross torque at rpm kgfÂm/rpm 38/1600
Engine oil quantity ˶(U.S.gal) 8.5(2.2)
Dry weight kg(lb) 350(772)
High idling speed rpm 2510Ü20
Low idling speed rpm 800Ü50
Rated fuel consumption g/ps.hr 140.2(at 1700rpm)
Starting motor V-kW 24-5
Alternator V-A 24-50
Battery V-AH 24-75
Fan belt deflection mm(in) 10~15(0.39~0.59)
(2) MAIN PUMP
Type Fixed displacement gear pump

Capacity cc/rev 35.6+33+7.6
Maximum operating pressure bar 210
Rated speed (Max/Min) rpm 3000/600
(3) MAIN CONTROL VALVE

Type Sectional
Operating method Mechanical
Main relief valve pressure bar 188/153
Flow capacity lpm 163
1-7
(4) POWER TRAIN DEVICES
Item Specification
Model F&S 300*16/4/-1(ZF SACH)

Torque converter Type 3 Element, 1 stage, 2 phase
Stall ratio 2.5 : 1
Type Full auto, Power shift
Gear shift(FWD/REV) 3/3
Transmission Control Electrical single lever type
FWD 1st : 4.578 2nd : 2.396 3rd : 0.994
Overhaul ratio
REV 1st : 4.593 2nd : 2.404 3rd : 0.996
Type Front-wheel drive type, fixed location
Axle
Gear ratio 10.545
Q'ty(FR/RR) Double : 4/2
Wheels Front(drive) 8.25-15-14 PR
Rear(steer) 8.25-15-14 PR
Travel Front wheel, Duo-servo/dry, wet disc brake/wet
Brakes
Parking Ratchet, internal expanding mechanical type
Type Full hydraulic, power steering
Steering
Steering angle 75.87äto both right and left angle, respectively
1-8
2) 80D-7E
(1) ENGINE
Model HYUNDAI D4DD-C7

Type 4 cycle turbocharged diesel type
Cooling Method Water cooling
Number of cylinders and arrangement 4 cylinders, In-line
Firing order 1-3-4-2
Combustion chamber type Direct injection
Cylinder bore X stroke mm(in) 104Ý115(4.1Ý4.5)
Piston displacement cc(cu in) 3907(238)
Compression ratio 17.5 : 1
Rated gross horse power ps/rpm 100/2300
Maximum gross torque at rpm kgfÂm/rpm 38/1600
Engine oil quantity ˶(U.S.gal) 8.5(2.2)
Dry weight kg(lb) 350(772)
High idling speed rpm 2510Ü20
Low idling speed rpm 800Ü50
Rated fuel consumption g/ps.hr 140.2(at 1700rpm)
Starting motor V-kW 24-5
Alternator V-A 24-50
Battery V-AH 24-75
Fan belt deflection mm(in) 10~15(0.39~0.59)
(2) MAIN PUMP
Type Fixed displacement gear pump

Capacity cc/rev 35.6+33+7.6
Maximum operating pressure bar 210
Rated speed (Max/Min) rpm 3000/600
(3) MAIN CONTROL VALVE

Type Sectional
Operating method Mechanical
Main relief valve pressure bar 188/153
Flow capacity lpm 163
1-9
(4) POWER TRAIN DEVICES
Item Specification
Model F&S 300*16/4/-1(ZF SACH)

Torque converter Type 3 Element, 1 stage, 2 phase
Stall ratio 2.5 : 1
Type Full auto, Power shift
Gear shift(FWD/REV) 3/3
Transmission Control Electrical single lever type
FWD 1st : 4.578 2nd : 2.396 3rd : 0.994
Overhaul ratio
REV 1st : 4.593 2nd : 2.404 3rd : 0.996
Type Front-wheel drive type, fixed location
Axle
Gear ratio 12.4
Q'ty(FR/RR) Double : 4/2
Wheels Front(drive) 8.25-15-14 PR
Rear(steer) 8.25-15-14 PR
Travel Front wheel, Duo-servo/dry, wet disc brake/wet
Brakes
Parking Ratchet, internal expanding mechanical type
Type Full hydraulic, power steering
Steering
Steering angle 75.87äto both right and left angle, respectively
1-10
4. TIGHTENING TORQUE FOR MAJOR COMPONENTS
NO ITEMS SIZE kgfÂm lbfÂft
1 Engine mounting bolt, nut M16Ý2.0 7.5 54

2 Engine Radiator mounting bolt, nut M10Ý1.5 6.9Ü1.4 50Ü10
3 Torque converter mounting bolt M10Ý1.5 6.9Ü1.4 50Ü10
4 Hydraulic MCV mounting bolt, nut M12Ý1.75 12.8Ü3.0 93Ü22
5 system Steering unit mounting bolt M10Ý1.5 6.9Ü1.4 50Ü10
6 Transmission mounting bolt, nut M16Ý2.0 7.5 54
7 Drive axle mounting bolt, nut M24Ý3.0 100Ü15 723Ü108
Power 41.3Ü6.2 300Ü45
8 Steering axle mounting bolt, nut M18Ý2.5
train
9 system Front wheel mounting nut M22Ý1.5 61.2Ü9.2 448Ü67
10 Rear wheel mounting nut M22Ý1.5 61.2Ü9.2 448Ü67
11 Counterweight mounting bolt M30Ý3.5 120Ü15 1555Ü239
12 Others Operator's seat mounting nut M 8Ý1.25 2.5Ü0.5 18.1Ü3.6
13 Head guard mounting bolt M12Ý1.75 12.8Ü3.0 93Ü22
1-11
5. TORQUE CHART
Use following table for unspecified torque.
1) BOLT AND NUT
(1) Coarse thread
8T 10T
Bolt size
kgfÂm lbfÂft kgfÂm lbfÂft
M 6Ý1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8Ý1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7
M10Ý1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60.0
M12Ý1.75 7.4 ~ 11.2 53.5 ~ 81.0 9.8 ~ 15.8 70.9 ~ 114
M14Ý2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 163
M16Ý2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18Ý2.0 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 344
M20Ý2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22Ý2.5 48.3 ~ 63.3 349 ~ 458 65.8 ~ 98.0 476 ~ 709
M24Ý3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30Ý3.0 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1656
M36Ý4.0 174 ~ 236 1261 ~ 1704 250 ~ 310 1808 ~ 2242
(2) Fine thread

8T 10T
Bolt size
kgfÂm lbfÂft kgfÂm lbfÂft
M 8Ý1.0 2.2 ~ 3.4 15.9 ~ 24.6 3.0 ~ 4.4 21.7 ~ 31.8
M10Ý1.2 4.5 ~ 6.7 32.5 ~ 48.5 5.9 ~ 8.9 42.7 ~ 64.4
M12Ý1.25 7.8 ~ 11.6 56.4 ~ 83.9 10.6 ~ 16.0 76.7 ~ 116
M14Ý1.5 13.3 ~ 18.1 96.2 ~ 131 17.9 ~ 24.1 130 ~ 174
M16Ý1.5 19.9 ~ 26.9 144 ~ 195 26.6 ~ 36.0 192 ~ 260
M18Ý1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20Ý1.5 40.0 ~ 54.0 289 ~ 391 53.4 ~ 72.2 386 ~ 522
M22Ý1.5 52.7 ~ 71.3 381 ~ 516 70.7 ~ 95.7 511 ~ 692
M24Ý2.0 67.9 ~ 91.9 491 ~ 665 90.9 ~ 123 658 ~ 890
M30Ý2.0 137 ~ 185 990 ~ 1339 182 ~ 248 1314 ~ 1796
M36Ý3.0 192 ~ 260 1390 ~ 1880 262 ~ 354 1894 ~ 2562
1-12
2) PIPE AND HOSE(FLARE TYPE)
Thread size(PF) Width across flat mm

kgfÂm lbfÂft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130
1" 41 21 152
1-1/4" 50 35 253
3) PIPE AND HOSE(ORFS TYPE)
Thread size(UNF) Width across flat mm

kgfÂm lbfÂft
9/16-18 19 4 28.9
11/16-16 22 5 36.2
13/16-16 27 9.5 68.7
1-3/16-12 36 18 130
1-7/16-12 41 21 152
1-11/16-12 50 35 253
4) FITTING
Thread size(PF) Width across flat mm

kgfÂm lbfÂft
1/4" 19 4 28.9
3/8" 22 5 36.2
1/2" 27 9.5 68.7
3/4" 36 18 130
1" 41 21 152
1-1/4" 50 35 253
1-13
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)
SAE 30
SAE 10W
Engine oil Engine oil 8.5
pan (2.2)
SAE 10W-30
SAE 15W-40
Torque 18
converter T/M oil ATF DEXRON III
transmission (4.8)
Axle Gear oil 12.5

(3.3) SAE 80W-90/API GL-5(DRY), MOBILFLUID 424(WET)
ISO VG32
Hydraulic Hydraulic 105
(27.7) ISO VG46
tank oil
ISO VG68
ASTM D975 No.1

Fuel tank Diesel fuel 150
(39.6)
ASTM D975 No.2
Fitting NLGI No.1

Grease -
(Grease nipple)
NLGI No.2
Brake
reservoir Hyd oil - DOT 3(DRY), AZOLA ZS10(Hydraulic oil SAE 10W : WET)
tank
Radiator
Antifreeze:Water 17 Ethylene glycol base permanent type
50:50 (4.5)
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
ÁC , even if the ambient temperature in daytime is expected to rise
engine start up is below 0Á
to 10ÁC or more.
Ι If any engine oil of API service class CF is used instead of class CH4 engine oil, the
frequency of oil change must be doubled.
1-14
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
1-15
GROUP 1 STRUCTURE
26 25 24 23 22
21
2 20
19
4 18
5
6 7 8 9 10 11 12 13 14 15 16 17
50DEOM21
1 Mast 10 Priority valve 19 Muffler

2 Lift cylinder 11 Transmission 20 Silencer
3 Tilt cylinder 12 Torque converter 21 Air cleaner
4 Control valve 13 Engine 22 Overhead guard
5 Fork 14 Exhaust pipe 23 Seat
6 Front wheel 15 Steering axle 24 Steering wheel
7 Drive axle 16 Steering cylinder 25 Control lever
8 Propeller shaft 17 Rear wheel 26 Steering unit
9 Hydraulic pump 18 Radiator
2-1
GROUP 2 REMOVAL AND INSTALLATION OF UNIT
Remove and install following units as explained in the flow chart.
1. MAST
1) REMOVAL
(1) SHAFT TYPE FORKS

Fork retainer
Η Lower the fork carriage until the forks are
approximately 25mm(1in) from the floor.
Θ Release fork retainer and remove cover. Hanger bar
Ι Slide one hanger bar at a time out of Cover
carriage assembly. Bolt
Κ Remove only one fork at a time. Fork
ö On larger forks it may be necessary to
use a block of wood. D507MS07
(2) HOOK ON TYPE FORKS(OPTION)

Η Lower the fork carriage until the forks are
Backrest
Θ Release fork anchor pins and slide one
Anchor pin
fork at a time toward the center of the
Carriage
carriage where a notch has been cut in
the bottom plate for easy fork removal.
Ι Remove only one fork at a time. Center notch
ö On larger forks it may be necessary to
use a block of wood. Fork
D507MS08
(3) BACKREST(HOOK ON TYPE)

Η Remove bolts securing backrest to fork
carriage lift backrest straight up and
remove it from carriage.
Backrest
Bolt
Carriage
D507MS09
2-2
(4) CARRIAGE
Crane
Η 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
Block
is level, this will prevent any binding when
the mast is raised. 50DS7EMS16
Θ While supporting lift chains, remove the

split pin and nuts from the chain anchor Outer mast
bolts of stationary upright.
Lift chain
Split
pin
Nut
80D7MS17
Ι Pull the chains out of the sheaves and

drape them over the front of the carriage. Mast
Carriage
Lift chain
Block
80D7MS18
2-3
Κ Slowly raise inner mast upright until mast
clears top of fork carriage. Move carriage
to work area and lower the mast.
Make sure that carriage remains on
floor and does not bind while mast is
being raised.
ö Inspect all parts for wear or damage.
Replace all worn or damaged parts.
80D7MS19
(5) PIPING
Η Remove the bulk hoses and clamps
attached to the cylinder.
Θ Remove the return hose from the down
control valve.
ö Put blind plugs in the piping immediately
after removing hoses.
This prevents the hydraulic oil from
flowing out and also prevents dust and
dirt from getting in.
50DS7EMS20
2-4
(6) LIFT CYLINDER
Η Loosen and remove hexagon bolts and Set screw
washers securing lift cylinders to inner

mast.
Θ Bind the lift cylinder with overhead hoist
rope and pull up so that the rope has no Inner mast
slack or binding.
Make sure the lift cylinder be tightened
firmly for safety.
Ι Loosen and remove hexagon bolts and Lift
nuts securing lift cylinders to outer mast. cylinder
Κ Using an overhead hoist, slowly raise the
inner mast high enough to clear lift
Outer mast
cylinder.
Λ Using an overhead hoist, draw out lift
cylinder carefully and put down on the
work floor.
Hexagon
bolt
Hexagon
nut
80D7MS21
(7) INNER MAST

Η Using an overhead hoist, raise the inner
mast straight and carefully draw out of
outer mast section.
Inner mast
Be careful the mast not to swing or fall.
Outer mast
80D7MS22
2-5
(8) TILT CYLINDER PIN
(9) MAST SUPPORT PIN
Attach a crane to the stay at the top of the
outer mast, and raise it.
Remove the mounting bolts and pins from Outer mast
drive axle, then slowly raise outer mast.
ö This operation is carried out under the
machine, so use a pit, or if there is no pit, Tilt cylinder
jack up the machine and loosen with an
impact wrench.
Tilt cylinder
pin
Mounting bolt
Mast support pin
Drive axle
80D7MS23
2-6
2) INSTALLATION
After assembling mast components totally without piping connections, install mast assembly to the
equipment.
ö Installation procedure for each of mast component is the reverse of the removal procedure.
(1) MAST SUPPORT PIN
Η Check the mast support pins for wear, then install pins into the mast support bracket and drive
axle.
Θ Jack up the machine so that the front is raised and then using an overhead hoist assemble outer
mast to drive axle unit.
Ι Tighten mounting socket bolts to drive axle unit.
ÂTightening torque : 49.2~66.6kgfÂm(355~481lbfÂft)
(2) TILT CYLINDER PIN
Hold the mast with a crane, operate the tilt control lever and align the holes, then knock the pin.
(3) LIFT CYLINDER INSTALLATION AND ADJUSTMENT
Η Assemble the lift cylinder inside the outer
mast, then tighten the stopper bolt. If the
cylinder assembly has been replaced,
adjust as follows so that the left and right
cylinders are synchronized at the maxi-
mum lifting height.
Θ Assemble the cylinder rod to the inner
mast, and check the left-to-right play of
the mast at the maximum lifting height.
ö If play is to LEFT, install adjustment shim
to LEFT cylinder.
ö If play is to RIGHT, install adjustment
D503RE03
shim to RIGHT cylinder.
ÂShim thickness : 1.0mm(0.04in)
2-7
2. POWER TRAIN ASSEMBLY
1) REMOVAL
D503RE04
(1) Mast
Refer to section on mast(Page 2-2)
2-8
(2) Brake piping
Disconnect the brake piping from the Brake pedal
wheel cylinder end.
Brake valve
Brake hose
Brake hose
Wheel
brake(RH)
Wheel
brake(LH)
Drive axle
50D7ERE05
(3) Parking brake cable

Disconnect parking brake cable from the Parking brake
lever
wheel brake assembly.
Parking brake
cable
Washer
Self locking pin Clevis pin
50D7ERE06
(4) Drive axle

ö Before removing the drive axle unit, drain
all of the oil from the axle.
Η Attach a crane to the tilt cylinder notches Transmission
on the dashboard and raise the machine.

Θ Loosen hexagonal bolts connecting drive
axle to propeller shaft.
Ι Put the block under the front axle and Bolt
support under the drive axle with a truck.
Truck
Drive
axle
50D7ERE07
2-9
Κ Remove drive axle mounting bolts from
the frame and then slowly pull out the
truck with drive axle to the front.
Bolt
Truck
Drive
axle
50D7ERE08
Λ Remove propeller shaft from the transmi-

ssion by loosening the mounting bolts.
Propeller shaft
Bolt
Spring washer
50D7ERE81
(5) Inching linkage

Remove the nut, clevis pins and self Inching
Nut pedal
locking pin. Bolt
Lever
Pedal
Bolt bracket
Washer Inching
Self locking pin sensor
50D7ERE09
2-10
(6) Transmission cooling piping
Η Disconnect cooling hose and connector Connector
from the transmission.
ö Make sure that the coolant be drained Radiator
from the hose.
Transmission
Hose Connector
Connector
50D7ERE10
(7) Torque converter

Cover
Η Remove the cover on bottom face of the
torque converter housing then remove Bolt
the 4 mounting bolts installed on the
engine flywheel. To rotate the flywheel,
remove 1 mounting bolt, then insert a
Mounting
turning tool in the mounting hole. One hole
man must turn the engine fan by hand Torque
while the other turns the flywheel. converter
Transmission housing
50D7ERE11
(8) Mounting bolts holding to flywheel

Torque converter
housing housing
Η Remove the transmission assembly from

the torque converter housing by loosen-
ing the mounting bolts. Bolt
Remove torque converter housing from Pin
the engine flywheel by loosening the
Bolt
mounting bolts and pins.
Transmission
50D7ERE16
2-11
Θ Using a moving truck slowly, pull out
transmission assembly to the front.
Propeller shaft
Bolt
Spring washer
50D7ERE81
2) INSTALLATION
Torque converter
Installation is the reverse order to removal, housing
but be careful of the following points.
(1) Tightening torque of mounting bolt for
torque converter housing. Bolt
Â5.8~8.3kgfÂm (42.0~60.0lbfÂft) Pin
Bolt
Transmission
50D7ERE16

drive axle.
Â85~115kgfÂm (615~832lbfÂft)
Bolt
Truck
Drive
axle
50D7ERE14
2-12
transmission and propeller shaft. Transmission
Â6.3~7.7kgfÂm (45.6~55.6lbfÂft)
Bolt
Propeller
shaft
Bolt
Truck
Drive
axle
50D7ERE15
2-13
3. ENGINE
Lever the torque converter, transmission and front axle inside the frame, then remove the engine
assembly.
1) REMOVAL
D503RE25
(1) Overhead guard

Tilt the overhead guard.
ö Refer to page 7-26 for operator's manual.
50DEMI66
2-14
(2) Remove the torque converter housing
cover and mounting bolts installed to
flywheel housing.
For details, see page 2-12.
(3) Engine accessory
Remove all wiring harnesses, cables and
hoses around the engine, dashboard and
frame.
Η Wiring harness to alternator and starter.
Θ Wiring harness for oil pressure and
engine water temperature gauges.
Ι Cables for meters, buttons and accelerator
pedal.
Κ Hoses to fuel tank and air cleaner.
Λ Exhaust pipe.
(4) Radiator hose
Open the drain valve of the radiator and
drain the cooling water, then remove the
radiator hose. 50D7ERE18
(5) Mounting bolt

Attach a crane to the engine hook and
raise, then remove mounting bolts. Raise
the engine slightly, slide towards the
radiator, then lift up.
ö When sliding the engine, be careful of the
collision engine and radiator.
50D7ERE19
2) INSTALLATION
Installation is the reverse order of removal, Loctite #243
but be careful of the following points.
(1) Tighten the engine mounting bolts and .
5.6-8.2kgf m
.
(40.6-59.3lbf ft)
nuts.
Mounting bolt
(2) Tighten the engine mounting bracket bolts.
7.5kgf.m(54.2lbf ft)
ö 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. Shim
ö Before installing the bolts, loctite in the Nut
holes should be removed by a tap.
50D7ERE20
2-15
(3) Tightening torque of mounting bolt
installing to torque converter housing.
Â5.5~8.3kgfÂm(39.8~60.0lbfÂft) Precleaner Radiator
cover(LH)
(4) Radiator hoses
ÂDistance to insert hose : 60mm(2.36in) Sub muffler
(5) Air cleaner hose

Insert the air cleaner hose securely and fit Air cleaner hose
a clamp.
Air cleaner
Distance to insert hose Loctite #243
ÂAir cleaner hose : 100mm(3.94in) Engine
ÂEngine end(MHI) : 70mm(2.7in) assy
Muffler
Loctite #243
Exhaust pipe
Loctite #243
50D7ERE21
2-16
4. STEERING AXLE
1) REMOVAL
D503RE35
Mounting bolt
50D7ERE30
(1) Counterweight
Hold the counterweight with hoist bars, and raise it with a crane.
Remove the mounting bolts, raise slightly and move it slowly to rear side.
ÂWeight of counterweight(standard)
50D-7E : 1,825kg(4,020lb)
60D-7E : 2,490kg(5,490lb)
70D-7E : 3,640kg(8,020lb)
80D-7E : 3,640kg(8,020lb)
2-17
(2) Rear wheel
Remove mounting bolt and hub nut with
socket wrench and then carefully take out
the tire assembly.
D503RE31
(3) Hose
Disconnect the hoses from steering axle
and then drain out oil.
Steering axle
Steering hose
50D7ERE32
(4) 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.
50D7ERE33
2-18
GROUP 1 STRUCTURE AND OPERATION
1. POWER TRAIN COMPONENT OVERVIEW
Drive axle Transmission Engine Steering axle
Propeller shaft Torque converter
50D7EPT01
The power train consists of the following components :

ÂTorque converter
ÂTransmission
ÂPropeller shaft
ÂDrive axle
Engine power is transmitted to the transmission through the torque converter.
The transmission is a hydraulically engaged three speed forward, three speed reverse power shift type
transmission.
The transmission outputs through universal joints to drive axle assembly.
The power transmitted to front axle drives front wheels.
3-1
2. TORQUE CONVERTER
5 1 2 3 4
D503TM01
1 Turbine 3 Pump 5 Input shaft

2 Stator 4 Transmission pump
The converter is working according to the Trilok-system, i.e. it assumes at high turbine speed the
characteristics, and with it the favorable efficiency of a fluid clutch.
The converter will be defined according to the engine power so that the most favorable operating
conditions for each installation case are given.
The Torque converter is composed of 3 main components :
Pump wheel - turbine wheel - stator(Reaction member)
These 3 impeller wheels are arranged in such a ring-shape system that the fluid is streaming through the
circuit components in the indicated order.
Pressure oil is constantly streaming out of the transmission pump through the converter. In this way, the
converter can fulfill its task to multiply the torque of the engine, and at the same time, the heat created in
the converter is dissipated through the escaping oil.
The oil, escaping out of the pump wheel, enters the turbine wheel and is there inversed in the direction of
flow.
According to the rate of inversion, the turbine wheel and with it also the output shaft, receive a more or
less high reaction moment. The stator(Reaction member), following the turbine, has the task to inverse
again the oil which is escaping out of the turbine and to delivery it under the suitable discharge direction
to the pump wheel.
Due to the inversion, the stator receives a reaction moment.
The relation turbine moment/pump moment is called torque conversion. This is the higher the greater
the speed difference of pump wheel and turbine wheel will be.
Therefore, the maximum conversion is created at standing turbine wheel.
With increasing output speed, the torque conversion is decreasing. The adoption of the output speed to
a certain required output moment is infinitely variable and automatically achieved by the torque
converter.
3-2
If the turbine speed is reaching about 80% of the pump speed, the conversion becomes 1.0 i.e. the
turbine moment becomes equal to that of the pump moment.
From this point on, the converter is working similar to a fluid clutch.
A stator freewheel serves to improve the efficiency in the upper driving range, it is backing up in the
conversion range the moment upon the housing, and is released in the coupling range.
In this way, the stator can rotate freely.
Function of a hydrodynamic torque converter(Schematic view)
TP = Torque of the pump wheel

TT = Torque of the turbine wheel
TR = Torque of the reaction member(Stator)
Pump wheel TR
Turbine wheel
From the engine
TT
TP
To the gearbox
Starting
condition 1 Reaction member nT = 0
1.5 2.5
(Stator) Machine stopped
Intermediate
condition 1 <1.5 <2.5 nT < n engine
Condition shortly
before the converter 1 1 nT = 0.8n engine
clutch is closed. 0
Turbine wheel is running with

about the same speed as
pump wheel.
D503TM02
3-3
3. TRANSMISSION
1) LAYOUT
1 2 3 4 5 6 7
14 10
15
12 11
16
13 12
13
50DS7ETM03
1 Flex plate for direct mount 7 Central shaft/input shaft PTO 12 Transmission housing - rear part
2 Converter 8 Connection, PTO ; coaxial, 13 Transmission housing - front part
3 Converter bell housing engine-dependent 14 Output flange
4 Transmission pump 9 Clutch shaft(KD) 15 Output shaft
5 Clutch shaft(KV) 10 Clutch shaft(KE) 16 Screen sheet
6 Input shaft/clutch shaft(KR) 11 Clutch shaft(KC)
3-4
2) INSTALLATION VIEW
1 2 3 4 5 6 7 7 5 10 3 2
8 8
14
13
9 10 9 12 11 9
FRONT VIEW REAR VIEW
50DS7EPT26
1 Converter 8 Filter
2 Direct mount via flex plate 9 Transmission mounting holes M16Ý1.5
3 Converter bell housing 10 Oil filter tube with oil dipstick
4 Transmission housing-front part 11 Oil drain plug 7/8"14 UNF 2B
5 Transport bracket 12 Output flange MECH 6C
6 Transmission housing-rear part 13 Identification plate
7 Filter head 14 Connection PTO;coaxial, engine-dependent
3-5
3) OPERATION OF TRANSMISSION
(1) Gearbox diagram
The multi-speed reversing transmission in countershaft design is power shiftable by hydraulically
actuated multi-disk clutches.
All gears are constantly meshing and carried on antifriction bearings.
The gear wheels, bearings and clutches are cooled and lubricated with oil.
The 3-speed reversing transmission is equipped with 5 multi-disk clutches.
At the shifting, the actual plate pack is compressed by a piston, movable in axial direction, which is
pressurized by pressure oil.
A compression spring takes over the pushing bask of the piston, thus the release of the plate
pack. As to the layout of the transmission as well as the specifications of the closed clutches in
the single speeds.
KV
KV
AN KR/PTO
AN/KR
KD KC
KD
KE
KE
AB
KC
AB
Legend:
Diagram Clutches
AN = Input
Driving direction Speed Clutch
KV = Clutch forward
1 KV/KC
KR = Clutch reverse
Forward 2 KV/KD
KC = Clutch 1st speed 3 KV/KE
KD = Clutch 2nd speed 1 KR/KC
KE = Clutch 3rd speed 2 KR/KD
Reverse
PTO = Power take-off
3 KR/KE
AB = Output
50DS7EPT32
3-6
(2) Forward
In forward, forward clutch and 1st, 2nd, 3rd clutch are engaged.
Forward clutch and 1st, 2nd, 3rd clutch are actuated by the hydraulic pressure applied to the
clutch piston.
Transmission diagram 1st gear forward
KV KV
AN/KR
AN KR/PTO
KD KC
KE
KD
AB
KE
Legend:
KC AN = Input
KV = Clutch forward
KR = Clutch reverse
KC = Clutch 1st speed
KD = Clutch 2nd speed
AB KE = Clutch 3rd speed
AB = Output
2nd gear forward 3rd gear forward
KV KV
AN/KR AN/KR
KD KD KC
KC
KE KE
AB AB
50DS7EPT33
3-7
(3) Reverse
In reserve, reserve clutch and 1st, 2nd, 3rd clutch are engaged.
Reverse clutch and 1st, 2nd, 3rd are actuated by the hydraulic pressure applied to the clutch
piston.
Transmission diagram 1st gear reverse
KV
KV
AN/KR
AN KR/PTO
KD KC
KD KE
KE AB
Legend:
KC AN = Input
KV = Clutch forward
KR = Clutch reverse
KC = Clutch 1st speed
AB KD = Clutch 2nd speed
KE = Clutch 3rd speed
AB = Output
2nd gear reverse 3rd gear reverse
KV KV
AN/KR AN/KR
KD KD KC
KC
KE KE
AB AB
50DS7EPT34
3-8
4) TRANSMISSION CONTROL
Transmission control see measuring points and oil circuit diagram see page 3-10.
The transmission pump which is necessary for the oil supply of the converter and for the transmission
control is located within the transmission on the engine-dependent input shaft.
The pump feed rate is Q=45˶/min, at nengine=1500min-1
This pump is sucking the oil out of the oil sump via the coarse filter, and delivers it to the main pressure
valve via the fine filter.
The 5 clutches of the transmission are controlled via the 5 proportional valves Y1 to Y5.
The direct proportional control with separate pressure modulation for each clutch controls the pressures
towards the clutches which are involved in the gear change.
This allows a hydraulic overlapping of the clutches to be engaged and disengaged.
The pressure modulation to the respective clutch is controlled by cup springs and proportional valves in
the package.
This creates spontaneous shifting without tractive effort interruption.
The following criteria are considered during the shifting operation:
- RPM of engine, turbine, gear chain and output
- Transmission temperature
- Shifting mode(upshifting, downshifting, reverse shifting and gear engagement out of neutral)
- Load condition(full and partial load, drive, coast, including consideration of load reversals during
shifting)
- Electronic inching
The main pressure valve limits the max, control pressure to 16+3 bar and release the main stream
towards the converter-and lubrication circuit.
The converter inlet incorporates a converter safety valve which protects the converter from high internal
pressure(opening pressure 11+2 bar).
Within the converter, the oil serves for transmitting the power according to the well-known hydrodynamic
principle(see Chapter torque converter page 3-2)
To avoid cavitation, the converter must always be completely filled with oil.
3-9
ÂH
Hydraulic circuit
57 56 58 53 55
KE KD KC KR KV
Gear-shift signal
Turbine speed
Y5 Y4 Y3 Y2 Y1
Output speed
Engine speed TCU
Speed central gear chain
Inch enable signal

Inch pedal signal 1 Oil sump temperature (OPTION)
Inch pedal signal 2 Oil temperature after the converter
Converter
51 64 67
Display
HDV
Park brake
feedback signal
WSV
FT
15 63
SKR
WT Lubrication GP
Main pressure
Controlled main pressure
Converter input pressure GF
Lubrication 16
Return flow into the tank
Oil sump
Current
Main oil circuit
50DS7EPT31
Driving Proportional valve under current

Gear Engaged clutches
direction Y1 Y2 Y3 Y4 Y5 N
1 ú ú KV KC
Forward 2 ú ú KV KD
3 ú ú KV KE
1 ú ú KR KC
Reverse 2 ú ú KR KD
3 ú ú KR KE
Engaged clutch KV KR KC KD KE
Curr. No. of meas. points 55 53 58 56 57
GF Coarse filter Y3 Proportional valve, clutch KC

GP Transmission pump Y4 Proportional valve, clutch KD
FT Filter Y5 Proportional valve, clutch KE
HVD Main pressure valve, 16+3bar KV KV clutch, forward
WSV Converter safety valve, 11+2bar KR KR clutch, reverse
SKR Lubrication of KR clutch KC KC clutch, 1st gear
WT Heat exchanger KD KD clutch, 2nd gear
Y1 Proportional valve, clutch KV KE KE clutch, 3rd gear
Y2 Proportional valve, clutch KR TCU Transmission control unit
3-10
5) GEAR SELECTOR(DW-3)
The gear selector is designed for the mounting on the steering column left side. By a rotative
motion, the positions(speeds) 1 to 3 are selected by tilting the lever, the driving direction(Forward (F)
- Neutral(N) - Reverse(R)).
For the protection from unintended start off, a neutral interlock is installed :
Position "N" - Controller lever blocked in this position
Position "D" - Driving
Gear positions Type plate

F
N N N D
D507PT12
3-11
Gear selector(DW-3)
LEVER FOR MECHANICAL

NEUTRAL INTERLOCK
CODING GEAR SELECTOR

N D
OUTPUT KD
FORWARD REVERSE NEUTRAL
SPEED
IN POSITION(NEUTRAL), 1 2 3 1 2 3 1 2 3
F-R NOT SWITCHABLE
AD1 B1
AD2 B2
AD3 B3
AD4 V
AD5 R
AD6 AS
AD7
A B C D
A B C D
X2 X1
F TYPE PLATE
GEAR POSITIONS CIRCUIT DIAGRAM SELECTOR
N N D SW
N A AD3(B3)
R
1 1 1
S6 S4 S5
2 2 2
GN
B AD2(B2)
BL
R C AD1(B1)
VI
C AD7(KD)
X1
F = Forward
RT
N = Neutral A ED1(+/VP)
S1 1
R = Reverse
3 2 GR
D = Mechanical neutral interlock S2 1
D AD6(N)
1 = 1st speed 3 2 GE D AD4(forward)
2 = 2nd speed
3 = 3rd speed S3 1
3 2 RS
D AD5(reverse)
CIRCUIT DIAGRAM SELECTOR
(+)
K1 = Relay starter interlock

X2 : A
(+)
K2 = Relay reverse lights
X1 : C
B1
B2
X1 : B
X1 : A
A1 = TCU(Transmission Control Unit)
A2 B3
V X1 : B A1 A2 = Gear selector
R X1 : C
AS X1 : D
K1 K2
(-)
50DS7EPT38
3-12
6) TRANSMISSION ERROR DISPLAY
(1) Function
The display can be used with the gear selector. It indicates speed and driving direction as well as
the activated inching.
When driving in the automatic mode, a bar indicator gives additionally also information about the
selected driving range; The automatic range is symbolized by arrows above and below the bar
indicator. In case of possible errors in the system, a wrench appears on the display, combined
with indication of the error number. Also sporadically occurring errors can be indicated.
f d Left side Right side
h S
T
O
P
b a c Central side g
D507CD33
a, f Automatic range(up and down shifting)

1 Bars
b, c, d, Preselected gear
2 Left side For the moment still without function
On the two alphanumeric 16-segment display, the electric control

Central and
3 unit issues the actual state of gear and driving direction. Besides,
Right side
a two digit error code will be indicated via these two segment
4 Spanner g Electronic control unit recognized an error, is flashing
5 Letters STOP h Immediate stop is required(At the moment not activated)
(2) Abbreviations
OC : Open circuit
SC : Short circuit
OP mode : Operating mode
TCU : Transmission control unit
EEC : Electronic engine controller
PTO : Power take off
3-13
(3) Display during operation
Symbol Meaning Remarks
F, N, R Actual gear and direction

Central side shows actual gear
1, 2, 3 Right side shows actual direction
NN Not neutral, waiting for neutral To engage a gear, first move shift selector to
(Central and right side) after power up or a reverse fault neutral position and again to F to R position
1 bar Manual mode 1st gear
2 bar Manual mode 2nd gear
3 bar Manual mode 3nd gear
3bars and 2 arrows Automatic mode a, f
Transmission neutral Cold start phase
Spanner flashing At least on fault active Select neutral to get fault code displayed
Changes between actual gear/direction while
Warning torque converter
WT driving, in neutral only displayed if no fault is
temperature
detected(spanner)
WS Warning sump temperature driving, in neutral only displayed if no fault is
detected(spanner)
WE Warning high engine speed driving, in neutral only displayed if no fault is
detected(spanner)
Transmission in neutral until parking brake is
Direction F or R selected while released.
PN parking brake engaged ö Machine starts to move after release of
parking brake.
Direction F or R selected while
F or R flashing turbine speed is to high ö Gear will engage when turbine speed drops
EE flashing
No communication with display
(central and right side)
3-14
(4) Display during AEB-Mode
Symbol Meaning Remarks

PL AEB-Starter is plugged at the
diagnostic plug
ST AEB-Starter-button is pressed
KA.....KE Calibrating clutch KC..KE, KV or KC, KD for 2 gear transmission
KV, KR KR resp. KC, KD, KE for 3 gear transmission
_and Kx Wait for start, initialization of

clutch Kx, x : C, D, E, V, R
óand Kx Fast fill time determination of
clutch Kx
=and Kx Compensating pressure
determination of clutch Kx
OK Calibration for all clutches finished Transmission stays in neutral, you have to
restart the TCU(ignition off/on) after removing
AEB-Starter
STOP AEB canceled(activation stopped) Transmission stays in neutral, you have to

restart the TCU(ignition off/on)
STOP and Kx AEB stopped, clutch Kx can't be Transmission stays in neutral, you have to
calibrated restart the TCU(ignition off/on)
Spanner and Kx Kx couldn't be calibrated, AEB Transmission stays in neutral, you have to
finished restart the TCU(ignition off/on)
Ā E Engine speed too low
Ą raise engine speed
Ă E Engine speed too high
Ą lower engine speed
Ā T Transmission oil temperature too
lowĄheat up transmission
Ă T Transmission oil temperature too
highĄcool down transmission
FT Transmission temperature not in Transmission stays in neutral, you have to
defined range during calibration restart the TCU(ignition off/on)
FB Operating mode not NORMAL or Transmission stays in neutral, you have to
transmission temperature sensor restart the TCU(ignition off/on)
defective or storing of Calibrated
values to EEPROM-has failed.
FO Outputspeed_not_zero Transmission stays in neutral, you have to
FN Shift lever not in Neutral position Transmission stays in neutral, you have to
FP Parkbrake_not_applied Transmission stays in neutral, you have to
STOP AEB-Starter was used incorrect or Transmission stays in neutral, you have to
is defective. Wrong device or restart the TCU(ignition off/on)
wrong cable used.
3-15
(5) Definition of the error codes
Η Introduction
The error codes consists of two hexadecimal numbers.
The first number shows the type of signal, the second number shows signal and the type of the
error.
Θ Description of error codes
First No. Meaning of number
1 hex Digital input signals

2 hex Analog input signals
3 hex Speed signals
4 hex Speed signals
7 hex Analog current output signals
8 hex Analog current output signals
9 hex Digital output signals
A hex Digital output signals
B hex Clutch errors
D hex Power supply
E hex High speed signals
F hex General errors
Ι List of error codes
Number Meaning of error code
11 hex Logical error at gear range signal

12 hex Logical error at direction select signal
21 hex Short circuit to battery voltage at clutch cutoff input

22 hex Short circuit to ground or open circuit at clutch cutoff input
25 hex Short circuit to battery voltage or open circuit at temperature sensor input
26 hex Short circuit to ground at temperature sensor input
31 hex Short circuit to battery voltage at engine speed input

32 hex Short circuit to ground or open circuit at engine speed input
33 hex Logical error at engine speed input
34 hex Short circuit to battery voltage at turbine speed input
35 hex Short circuit to ground or open circuit at turbine speed input
36 hex Logical error at turbine speed input
37 hex Short circuit to battery voltage at internal speed input
38 hex Short circuit to ground or open circuit at internal speed input
39 hex Logical error at internal speed input
3-16
3A hex Short circuit to battery voltage or open circuit at output speed input
3B hex Short circuit to ground or open circuit at output speed input
3C hex Logical error at output speed input
71 hex Short circuit to battery voltage at clutch KC

72 hex Short circuit to ground at clutch KC
73 hex Open circuit at clutch KC
74 hex Short circuit to battery voltage at clutch KD
75 hex Short circuit to ground at clutch KD
76 hex Open circuit at clutch KD
77 hex Short circuit to battery voltage at clutch KE
78 hex Short circuit to ground at clutch KE
79 hex Open circuit at clutch KE
84 hex Short circuit to battery voltage at clutch KV

85 hex Short circuit to ground at clutch KV
86 hex Open circuit at clutch KV
87 hex Short circuit to battery voltage at clutch KR
88 hex Short circuit to ground at clutch KR
89 hex Open circuit at clutch KR
91 hex Short circuit to ground at relay reverse warning alarm

92 hex Short circuit to battery voltage at relay reverse warning alarm
93 hex Open circuit at relay reverse warning alarm
94 hex Short circuit to ground at relay starter interlock
95 hex Short circuit to battery voltage at relay starter interlock
96 hex Open circuit at relay starter interlock
97 hex Short circuit to ground at park brake solenoid
98 hex Short circuit to battery voltage at park brake solenoid
99 hex Open circuit at park brake solenoid
3-17
B1 hex Slippage at clutch KC

B2 hex Slippage at clutch KD
B3 hex Slippage at clutch KE
B5 hex Slippage at clutch KV
B6 hex Slippage at clutch KR
D1 hex Short circuit to battery voltage at power supply for sensors

D2 hex Short circuit to ground at power supply for sensors
D3 hex Low voltage at battery
D4 hex High voltage at battery
D5 hex Error at valve power supply 1
D6 hex Error at valve power supply 2
E5 hex Communication failure on devicenet
F1 hex General EEPROM fault

F2 hex Configuration lost
F3 hex Application error
3-18
6) ELECTRONIC CONTROL FOR POWER TRANSMISSION
(1) Description of the basic functions
The powershift transmission 3 WG-94 EC of series WG-90 is equipped with the electronic
transmission control EST-65 specially developed for this purpose.
The system process the driver command according to the following criteria:
ÂGear determination depending on driving speed and load condition.
ÂIf required, protection against operating errors is possible via electronic protection (programming)
ÂProtection against overspeeding(on the basis of engine and turbine speed)
ÂPressure cut-off possible(vehicle-specific, only after coordination with ZF)
ÂSwitch-over possibility for automatic / manual operation
ÂDownshifting functions possible
ÂElectronic inching
3-19
6
8
7
4
11
14 12
9
3 13
2
10
16 17
15
18 19
20
1
50DS7EPT17
1 Inching pedal 11 Temperature measuring point after the

2 Gear selector converter (No. 63)
3 Display 12 Inductive sensor - turbine speed
4 Optical warning 13 Inductive sensor - engine speed
5 Switch for driving program 14 Temperature measuring point for the converter
Manual/Automatic (No. 64)
6 CAN connection 15 Proportional valve Y3 - KC clutch
7 TCU 16 Proportional valve Y2 - KR clutch
8 Diagnostic Laptop with ZF diagnostic 17 Proportional valve Y1 - KV clutch
system Testman/Pro 18 Proportional valve Y5 - KE clutch
9 Inductive sensor - speed of central gear chain 19 Proportional valve Y4 - KD clutch
10 Speed sensor - output 20 Ergopower transmission 3 WG-94 EC
3-20
(2) Inching device
This function is especially suitable for lift trucks. Without modifying the engine speed, it allows a
continuously variable reduction of the driving speed to such a level that operation at a very low
speed is possible. In this way, the driver can move the vehicle to a certain position with high
accuracy.
At the same time, a large part of the engine power is available for driving the hydraulic lifting
system, due to the high engine speed.
The electrical inching is operated via a separate inching pedal fitted with an angle-of-rotation
sensor.
By means of the proportional valve technology, the TCU controls the pressure in the driving
direction clutch in such a way that the driving speed is adjusted in accordance with the position of
the inching angle-of-rotation sensor. Clutch overloading is prevented by the electronic protection.
ö After each readjustment of the inching linkage, the IPK(Inch Pedal Calibration-Inch Sensor
Calibration) must be carried out.
During the inching calibration mode, the position of the inching pedal in neutral position and at full
actuation is determined by the calibration process and stored in theTCU.
ö The inching function does not become active until successful completion of AEB and IPK start.
3-21
4. TRANSMISSION MEASURING POINTS AND CONNECTIONS
The measurement have to be carried out with hot transmission(about 80~95ÁC)
63 21 68 64 69 64 11 21 67 63
55
47
10 15
51 16
58
53
34
56
57
AN/KR KV 57 67
71 AN/KR
KV
70
Y1
Y1
KD Y2
Y2
KC KC KD Y4
Y4
KE
Y5
Y5
Y3 ZF
Y3
4661 401 059
AB
4661 301 059
KE AB
50DS7ETM04
3-22
1) Measuring points for pressure oil and temperature
Port Description Size

51 Before the converter - opening pressure 11 2 bar M10x1
53 Reverse clutch KR 16 3 bar M10x1
55 Forward clutch KV 16 3 bar M10x1
56 Clutch KD 16 3 bar M10x1
57 Clutch KE 16 3 bar M10x1
58 Clutch KC 16 3 bar M10x1
63 Temperature after the converter 100Á
C ;short-term 120Á
C M14x1.5
64 Temperature sensor M12x1.5
67 System pressure 16 3 bar M10x1
2) Valves and connections

10 Breather M10x1
15 Connection towards heat exchange 7/8" 14 UNF
16 Connection from heat exchanger 7/8" 14 UNF
68 Connection after fine filter 9/6-18 UNF-2B
69 Connection before fine filter 7/8" 14 UN 2A
70 Converter safety valve(WSV)
71 Main pressure valve(HDV)
3) Inductive transmitters and speed sensor

11 Inductive transmitter n Engine M18x1.5
21 Inductive transmitter n Turbine M18x1.5
34 Speed sensor n Output -
47 Inductive transmitter n Central gear train M18x1.5
3-23
5. DIFFERENTIAL CARRIER ASSEMBLY
1) STRUCTURE
3 2 1
4 5
50D7EAX02
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.
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.
3-24
6. DRIVE AXLE
1) STRUCTURE
3 4 2
1 5
50D7EAX01
1 Differential carrier ass'y 3 Drive wheel 5 Parking brake

2 Drive shaft 4 Disc brake
OPERATION
The 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.
3-25
2) DRIVE AXLE
1 2 3 4 5 6 7 8 9 10 11 12 13 14
50D7EAX03
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
OPERATION
Drive axle 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 shaft (8) are connected with spline and the drive shaft (8) connect to
planetary gear (2), inner hub (6) and finally drive wheels.
3-26
3) DRIVE AXLE TIGHTENING TORQUE
1 9 2 3 4 5 6
7 8
10 11
50D7EAX04
No Item Specification
1 Inner carrier 2.2Ü0.3kgfÂm (15.9Ü2.2lbfÂft)

2 Spindle 12Ü0.5kgfÂm (86.8Ü3.6lbfÂft)
3 Service piston 1.5Ü0.1kgfÂm (10.8Ü0.7lbfÂft)
4 Adjuster nut 1.0Ü0.2kgfÂm (7.2Ü1.4lbfÂft)
5 Differential cap 16Ü0.5kgfÂm (116Ü3.6lbfÂft)
6 Differential case 6.0Ü0.5kgfÂm (43.4Ü3.6lbfÂft)
7 Ring gear 13.5Ü0.5kgfÂm (97.6Ü3.6lbfÂft)
8 Differential carrier assembly 18.0Ü0.5kgfÂm (130Ü3.6lbfÂft)
9 Wheel hub rolling resistant 3.0Ü0.3kgfÂm (21.7Ü2.2lbfÂft)
10 Parking brake 20.0Ü0.9kgfÂm (144.7Ü6.5lbfÂft)
11 Brake drum 12.0Ü0.5kgfÂm (86.8Ü3.6lbfÂft)
3-27
4) DISK BRAKE
1 2 6 7
3 4 5 8
2 3
View "A"
50D7EAX05
1 Spindle 4 Service piston 7 Drive shaft

2 Steel plate 5 Service collar 8 Parking brake
3 Disk plate 6 Service piston adjust bolt
OPERATION
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 maintain its lining as
drum type brake do. Also with self-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).
3-28
7. TIRE AND WHEEL
B507AX68
1 Wheel rim 3 Lock ring 5 Valve assembly

2 Tire 4 Side ring 6 Wheel nut
1) The tire acts 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.
2) 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.
3-29
GROUP 2 OPERATION AND MAINTENANCE
1. OPERATION
1) DRIVING PREPARATION AND MAINTENANCE
Prior to the commissioning of the transmission, take care that the prescribed oil grade will be filled in
with the correct quantity. At the initial filling of the transmission has to be considered that the oil
cooler, the pressure filters as well as the pipes must get filled with oil.
According to these cavities, the quantity of oil to be filled in, is greater than at the later oil fillings in
the course of the usual maintenance service.
ö Because the converter and the oil cooler, installed in the vehicle, as well as the pipes can empty at
standstill into the transmission, the oil level check must be carried out at engine idling speed
and operation temperature of the transmission.
At the oil level check, the vehicle has to be secured against rolling by blocks, articulated
vehicles additionally against unintended turning-in.
2) DRIVING AND SHIFTING
(1) Neutral position
Neutral position will be selected via the gear selector.
After the ignition is switched on, the electronics remains in the waiting state. By the position
NEUTRAL of the gear selector, the TCU becomes ready for operation.
A gear can be engaged.
(2) Starting
The starting of the engine has always to be carried out in the NEUTRAL POSITION of the gear
selector.
For safety reasons it is to recommend to brake the vehicle securely in position with the parking
brake prior to start the engine.
After the starting of the engine and the preselection of the driving direction and the gear, the
vehicle can be set in motion by acceleration.
At the start off, the converter takes over the function of a master clutch.
On a level road it is possible to start off also in higher gears.
- Upshifting under load.
Upshifting under load will be then realized if the vehicle can continue to accelerate by it.
- Downshifting under load.
Downshifting under load will be then realized if more traction force is needed.
3-30
- Upshifting in overrunning condition.
In the overrunning mode, the upshifting will be suppressed by accelerator pedal idling position, if
the speed of the vehicle on a downgrade should not be further increased.
- Downshifting in overrunning condition.
Downshifting in overrunning mode will be then carried out if the vehicle should be related.
If the vehicle will be stopped and is standing with running engine and engaged transmission, the
engine cannot be stalled. On a level and horizontal roadway it is possible that the vehicle begins
to crawl, because the engine is creating at idling speed a slight drag torque via the converter.
It is convenient to brake the vehicle at very stop securely in position with the parking brake. At
longer stops, the controller has to be shifted to the NEUTRAL POSITION.
At the start off, the parking brake has to be released. We know from experience that at a
converter transmission it might not immediately be noted to have forgotten this quite normal
operating step because a converter, due to its high ratio, can easily overcome the braking torque
of the parking brake.
Temperature increases in the converter oil as well as overheated brakes will be the consequences
to be find out later.
Neutral position of the selector switch at higher vehicle speed(above stepping speed) is not
admissible.
Either a suitable gear is to be shifted immediately, or vehicle must be stopped at once.
3) COLD START
At an oil temperature in the shifting circuit <-12ÁC, the transmission must be warmed-up for some
minutes.
This must be carried out in neutral with an increased engine speed(about 1500min-1).
Until this oil temperature is reached, the electronics remains in neutral, and the symbol of the cold
start phase will be indicated on the display.
Indication on the display:

After the indication on the display is extinguished, the full driving program can be utilized out of
"NEUTRAL".
4) OIL TEMPERATURE
The oil temperature in the transmission sump is in the electrohydraulic control unit.
The service temperature in the sump of 60~90ÁC must not be exceeded.
By overstepping results by 105ÁC notice "WS" on the display.
At a trouble-free unit and an adequate driving mode, a higher temperature will not occur.
The notice "WS" results at the display, the vehicle has to be stopped and controlled for external oil
loss and the engine must run with a speed of 1200-1500min-1 at NEUTRAL POSITION of the
transmission.
3-31
Now, the temperature must drop quickly(in about 2-3minutes) to normal values. If this is not the
case, there is a trouble pending, which must be eliminated prior to continue working.
The monitoring of the oil temperature(behind the converter) is additionally on the temperature
gauge which is located on the dashboard.
Operating temperature behind the converter at least 65ÁC and 100ÁC in continuous operation, a
short-time increase up to max. 120ÁC is permitted.
The temperature is measured on the measuring point "63" (see schedule of measuring points-3-22)
3-32
2. MAINTENANCE
1) TRANSMISSION
(1) Oil level check
At the oil level check, the vehicle has to be secured against rolling with blocks.
The oil level check must be carried out as follows :
- Oil level check(weekly)
- At horizontally standing vehicle
- Transmission in neutral position "N"
- In the cold start phase, the engine must be running about 2-3minutes at idling speed, and the
marking on the oil dipstick must then be lying above the cold start mark "COLD"
- At operating temperature of the transmission(about 80~90ÁC)
- At engine idling speed
- Loosen oil dipstick by counterclock rotation, remove and clean it
- Insert oil dipstick slowly into the oil level tube until contact is obtained, and pull it out again.
- On the oil dipstick, the oil level must be lying in the zone "HOT"
- Insert the oil dipstick again, and tighten it by clockwise rotation
If the oil level has dropped in operating temperature condition below the "HOT" zone, it is
absolutely necessary to replenish oil.
An oil level above the "HOT" marking, is leading to a too high oil temperature.
3-33
(2) Oil change and filter replacement intervals
ö First oil change after 100 operating hours in service.
Every further oil change after 1000 operating hours in service, however at least once a year.
At every oil change, the fine filter has to be replaced.
Η Oil change and oil filling capacity
The oil change has to be carried out as follows. At operating temperature of the transmission,
horizontally standing vehicle open the oil drain plug and drain the used oil.
- Clean oil drain plug with magnetic insert and surface on the housing and install again along
with O-ring.
- Fill in oil(about 24 liters).
(Sump capacity, external oil capacities e. g. in the heat exchanger, in the lines etc. are depend-
ed on the vehicle).
The indicated value is a guide value.
ö It is imperative to pay attention to absolute cleanliness of oil and filter.
Binding is in any case the making on the oil dipstick.
- Start the engine-idling speed
- Transmission in neutral position "N"
- Top up oil up to the marking "COLD"
- Brake the vehicle securely in position and warm up the transmission
- Shift all controller positions through
- Check the oil level once more and top up oil once more if necessary
- On the oil dipstick, the oil level must be lying in the zone "HOT"
- Insert the oil dipstick again and tighten it by clockwise rotation
ö At the initial filling of the transmission has to be considered that the heat exchanger, the pressure
filter as well as the pipes must get filled with oil.
According to these cavities, the oil capacity to be filled in is greater than at the later oil fillings in
the course of the usual maintenance service.
Θ Filter replacement
At the replacement of the filter in the main oil steam, pay attention that no dirt or oil sludge can
penetrate into the circuit.
At the mounting of the filter, any exertion of force has to be avoided.
ö Treat the filter carefully at the installation, the transport and the storage.
Damaged filters must no more be installed.
The mounting of the filter must be carried out as follows:
- Cover the gasket with a small amount of oil.
- Screw the filter in until contact with the sealing surface is obtained and tighten it now by hand
about 1/3 to 1/2 turn.
3-34
4 4
2 1 3
50DS7EPT19
Legend:
1 = Oil filler tube with oil dipstick
2 = Mounting provision for oil filler tube with oil dipstick(option)
3 = Oil drag plug 7/8" 14 UNF 2B
4 = Fine filter
Oil dipstick
MEASURED AT LOW
IDLING-NEUTRAL HOT COLD
HOT
D507PT20
3-35
2) DRIVE AXLE
(1) General information
Drive axles generate small metal wear particles at a fairly steady rate, especially during the break-
in period. If these fine, but hard particles are allowed to circulate in the lubricant, along with
external moisture and dirt, internal components will wear at a much faster rate than normal.
(2) Magnets and magnetic drain plugs
Planetary axles are equipped with magnetic drain plug that have a minimum pick-up capacity of
0.57kg(20 ounces) of low carbon steel. The drain plug must be checked for metal particles at
every oil change interval.
ö Hyundai recommends replacing the magnetic drain plug each time the oil is changed.
Use the correct part. Pipe plugs will leak if used as a drain plug.
The magnetic drain plug can be reused if, after cleaning, the plug has a minimum pick-up capacity
of 0.57kg(20 ounces) of low carbon steel.
(3) Breather
Cover the breather when steam cleaning the housing. If the breather is not covered, water
can enter the housing and contaminate the oil.
Breathers release pressure and vacuum condensation to minimize premature oil and component
failure.
(4) Oil level
Check and adjust oil
To prevent serious eye injury, always wear safe eye protection when you perform vehicle
maintenance or service.
ö Fill and drain plugs are located in both brake housing and the main housing.
Η Make sure the vehicle is on a level surface.
ö For axles with a common oil level that have drain and fill plugs only in the axle assembly, proceed
to step Ι.
Θ Rotate the wheels so that the "Oil level lines" on the wheel ends are parallel to the ground.
Ι Clean the area around the fill/level plug.
Remove the fill/level plug from the wheel
ends and the axle housing bowl. The oil
level must be even with the bottom of the
HORZ
hole of the fill/level plug. OIL FILL
LEVEL
FILL/LEVEL
PLUG
D507AX67
3-36
Κ If oil flows from the hole when you loosen the plug : The oil level is high. Let the oil drain to the
correct level.
ö Do not fill only through the axle housing bowl.
Λ If the oil level is below the bottom of the hole of the fill/level plug : Fill the axle at each wheel
end and the axle housing bowl to the bottom of the fill plug hole with the specified oil. Wait and
allow the oil to flow through the axle.
Check the oil level again and fill to the specified level if necessary.
Μ Install the fill/level plugs. Apply thread compound and tighten. Refer to the "Torque table".
(5) Oil change
Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving.
Support the vehicle with safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury can result.
Η Make sure the vehicle is on a level surface.
Put large containers under the axle and wheel ends.
Θ Raise the vehicle so that the wheels are off the ground. Support the vehicle with safety stands.
Ι Rotate the wheels so that the "fill/level" plugs in the wheel ends are toward the ground.
Κ Remove the drain plugs from both brake housing and the main housing. Drain and discard the oil
properly. Clean the plug.
Λ Install the drain plugs in both brake housings and the main housing. Apply thread compound and
tighten. Refer to the "torque table".
Μ Rotate the wheels so that the " oil level lines" on the wheel ends are parallel to the ground.
Lower the vehicle.
Ν Clean the area around the fill/level plug.
Remove the fill/level plug from the wheel ends and the axle housing bowl.
ö Do not fill only through the axle housing bowl.
Ξ Fill the axle at each wheel end and the axle housing bowl to the bottom of the fill plugs hole with
the specified oil. Wait and allow the oil to flow through the axle. Check the oil level again and fill
to the specified level if necessary.
Ο Install the fill/level plugs. Apply thread compound and tighten. Refer to the "torque table".
(6) Oil change intervals and specifications

Off-highway operation intervals* Oil specification Remarks
Recommended Check Petroleum Synthetic Transmission oil Initial use or
initial oil change oil level oil change oil change refill
100 operating 250 operating 1,000 operating - Transmission oil OK to use only
hours hours* hours or twice a for refill
year(whichever
comes first)
* The checking interval depends on individual operating conditions, speeds and loads, severe
operating conditions may require more frequent checks.
3-37
3. TROUBLESHOOTING
1) DRIVE AXLE
(1) BRAKE LEAKS ACTUATION FLUID
Condition Possible cause Correction
Internal leak : Fluid 1. Worn or damaged piston seal. 1. Replace piston seals.
bypasses seals into axle 2. Melted or extruded piston seals. 2. Correct cause of overheating and replace
and fills axle with fluid seals.
and blows out breather 3. Corrosion, pitting, wear or other
damage, marks, scratches to 3. Clean, smooth, rework or replace affected
or empties brake fluid
piston and/or brake housing bore parts.
reservoir.
in area of seal/sealing lips.
External leak 1. Loose bleeder screw. 1. Tighten bleeder screw to 2.0~2.7kgfÂm(15-20 lb-ft)
2. Loose inlet fitting or plugs. 2. Tighten inlet fitting to 3.4~4.8kgfÂm(25-35 lb-ft)
3. Damaged inlet fitting or plugs or 3. Replace inlet fitting or plug and O-ring if used.
damaged seats.
(2) BRAKE NOISE AND VIBRATION
Brakes product noise, Incorrect axle fluid and/or friction 1. Use only approved materials.
chatter, vibration. material used. 2. Drain and flush fluid from axle. Replace with
approved fluid.
3. Replace all friction discs. Thoroughly clean or
replace stationary discs.
3-38
(3) BRAKE OVERHEATS
Overheating due to Inadequate coolant flow or heat 1. Install brake cooling system if not already
excessive duty cycle. exchange. installed on vehicle.
2. Re-analyze and re-size brake cooling system
if necessary.
Inadequate coolant flow Low pump output, blocked filter or Check pump output at different operating
coolant lines. modes. Replace filter and check lines.
Low or no coolant. 1. Improper fill or leaks. 1. Check for proper fill level.
2. Leaking face seal. 2. Replace or reinstall face seal assembly.
3. Loose or damaged plugs. 3. Tighten drain, fill or forced cooling plug.
Replace if damaged.
4. Deteriorated or inadequate 4. Dissemble, clean, re-seal and re-assemble
sealant used at joint. brake housing joint.
Brake drags. 1. More than 1.4bar(20psi) pressure 1. Repair hydraulic system so pressure is less
applies when brakes released. than 1.4bar(20psi) when brakes released and
while machine is operating in any mode.
2. Damaged piston return spring 2. Repair or replace piston return spring
assembly. assembly.
3. Piston not returning. 3. Check piston seals and seal separator.
4. Wrong cooling and/or actuation 4. Check piston seals and seal separator for
fluid used. swelling or damaged. Replace as necessary.
Purge system and use correct fluid.
5. Tight or damaged splines(eg. 5. Repair or replace parts.
friction disc-to-hub driver).
(4) BRAKE DOES NOT APPLY
Low or no pressure to 1. Empty fluid reservoir. 1. Fill reservoir to correct level with specified
brake fluid.
2. Damaged hydraulic system. 2. Repair hydraulic system.
3. Leaked of brake actuation fluid. 3. Refer to "Brake leaks actuation fluid" in this
section.
4. Parking brake not adjusted 4. Adjust parking brake lever as described in
properly. assembly of this manual.
3-39
(5) BRAKE DOES NOT RELEASE
Vehicle does not move Damaged hydraulic system. Repair hydraulic system.
Brakes dragging 1. More than 1.4bar(20psi) pressure 1. Repair hydraulic system so pressure is less
applied when brakes released. than 1.4bar(20psi) when brakes released and
while machine is operating in any mode.
2. Damaged piston return spring 2. Repair or replace piston return spring
assembly. assembly.
3. Piston not returning. 3. Check piston seals for swelling or damage.
Replace as necessary.
4. Wrong cooling and/or actuation 4. Check piston seals for swelling or damage.
fluid used. Purge system and use specified fluid.
5. Parking brake not adjusted prope- 5. Adjust parking brake lever as described in
rly. assembly of this manual.
(6) BRAKING PERFORMANCE
Noticeable change or 1. Inadequate actuation fluid supply 1. Replenish fluid in brake system. Check for
decrease in stopping to brakes. leakage and correct cause.
performance. 2. Inadequate pressure to apply 2. Check brakes apply system. Check for
brakes. leakage in brake system or brakes, and
correct cause.
3. Worn or damaged discs. 3. Inspect and replace discs if necessary.
öAs disc wear occurs, make sure brake
system can supply adequate fluid to fully
apply brakes.
4. Overheated seals and/or discs. 4. Inspect and replace discs and seals if
necessary.
5. Dirty or contaminated cooling 5. Drain and flush cooling fluid from brakes and
fluid. entire brake system. Replace with approved
fluid. In some cases, it may necessary to
replace discs. Clean or replace filter.
Brake does not fully 1. Empty fluid reservoir. 1. Fill reservoir to correct level with specified
apply. fluid.
2. Damaged hydraulic system. 2. Repair hydraulic system.
3. Leakage of brake actuation fluid. 3. Refer to "Brake leaks actuation fluid" in this
section.
Brakes fell spongy/soft. Brakes or brake system not properly Bleed brakes and brake system.
bled.
3-40
(7) DIFFERENTIAL
No Problem Cause Remedy
1 Constant noise in differential. 1. Oil is not enough. Â Refueling lubricating oil.

(Replace interval : 50 hrs first, then
every 500 hrs)
2. Wrong kind of oil. ÂChange lubricating oil.
3. Wheel bearings out of adjustment ÂChange bearing.
or have a defect.
4. Drive gear and pinion not in adjust- ÂRe-assemble.
ment for correct tooth contact.
5. Teeth of drive gear and pinion ÂChange damaged gear.
have been damaged or worn.
6. Gear backlash is too much or too ÂChange differential gear set.
little.
7. Loose or worn on pinion bearings. ÂChange bearing.
8. Loose or worn on side earing. ÂChange bearing.
2 Noise at different intervals. 1. Ring gear does not run even.
(1) Bolts on drive gear are not ÂTighten bolts.
tightened correctly.
(2) Drive gear has a defect (warped) ÂChange differential pinion gear or
spider.
2. Loose or broken differential ÂChange bearing.
bearings.
3 Noise on turns only. 1. Differential pinion gears are tight ÂChange differential pinion gear or
on the spider. spider.
2. Side gears are tight in differential ÂChange differential side gear.
case.
3. Differential pinion or side gears ÂChange differential gear set.
have a defect.
4. Thrust washers worn or have a ÂChange differential washer.
damage.
5. Too much clearance (backlash) ÂChange differential gear set.
between side gears and pinions.
4 Leakage of the oil. 1. Leakage through axle hub carrier.
(1) Too much oil. ÂAdjust oil level
(2) Wrong kind of oil. ÂChange lubricating oil.
(3) Much restriction on air eather. ÂChange air breather.
2. Leakage around pinion shaft.
(1) Too much oil. ÂAdjust oil level.
(2) Wrong kind of oil. ÂChange lubricating oil.
(3) Much restriction on air eather. ÂChange air breather.
(4) Oil seal worn or not installed ÂChange oil seal.
correctly.
5 Drive wheels do not rotate. 1. Broken axle shaft.
(1) Loose wheel bearings. ÂRe-assemble wheel bearings.
(2) Axle shaft too short. ÂReplace drive shaft.
(3) Loose flange studs or nuts. ÂTighten studs or nuts.
2. Drive gear teeth have been ÂChange damaged drive gear set.
damaged.
3. Side gear on differential damaged. ÂChange damaged gear.
4. Differential pinion shaft or spider ÂChange damaged gear.
broken.
3-41
2) TRANSMISSION
(1) GENERAL INSPECTION WHILE DRIVING
No Problem Cause
1 Failure at the specific gear 1. Low oil pressure or no pressure.

stage 1) No oil, low level or high oil viscosity.
2) Loose inching control valve connection, incorrect adjustment or
damage.
3) Inching valve spool sticked or open.
4) Oil pump damage or defect.
5) T/C pump gear side bolt breakage or gear not meshing with
pump.
6) Main regulator valve sticked or open.
7) Oil circuit clogged or strainer contaminated.
8) T/M inside leakage.
Control valve gasket damage.
- Clutch shaft metal sealing wear or damage.
- Clutch piston seal damage or wear.
9) Control valve gasket wear cause oil leakage.
2. Abnormal connection of outer line of cooler.
3. Mechanical defect inside the T/M
2 Gear shift failure 1. Low oil pressure.
2. Main regulator valve does not move.
3. Malfunctioning of solenoid or relative electric components.
3 T/M overheating 1. Clogged cooling line.
2. Oil level is too high or too low.
3. Low pump pressure, pump wear or defect.
4. Partial clutch wear or slip
5. Air mixed with oil, air leakage at the pump input port.
6. Insufficient oil flow through the T/C.
7. Overload on the machine.
8. Too excessive inching operation.
9. Too excessive stall operation of T/C.
10. Cooler bypass valve stick or open. Oil flow insufficient through oil
cooler.
3-42
No Problem Cause
4 Slow clutch meshing or failure 1. Low oil pressure.

2. Low converter oil pressure.
3. Air mixed with oil
1) Air mixed through the pump input port.
2) Low oil level
4. Abnormal adjustment of inching valve linkage.
5 Reverse gear shift failure 1. Excessive wear of disk and plate at reverse clutch.
2. Oil leakage from seal.
3. Reverse clutch components defect.
1) Metal sealing wear or defect.
2) Clutch piston seal wear or defect.
3) Another components damaged.
4. Malfunction of solenoid or related electric parts.
6 Forward gear shift failure 1. Excessive wear of disk and plate at forward clutch.
2. Oil leakage from seal.
3. Forward clutch components defect.
1) Metal sealing wear or defect.
2) Clutch piston seal wear or defect.
3) Another components damaged.
4. Malfunction of solenoid or related electric parts.
7 Low stall speed 1. Incorrect engine performance.
2. Torque converter stator failure.
8 High stall speed at all of gear 1. Low oil level.
stage 2. Air mixed with oil.
3. Clutch slip.
4. T/C malfunctioning.
9 High stall speed at partial 1. Clutch line leakage.
direction or speed 2. Clutch defect.
10 Slow clutch meshing and rough 1. Incorrect adjustment of inching valve.
gear shift 2. Inching valve not closed or clogged orifice.
3. Low main pressure.
4. Low pressure of direction clutch.
5. Oil leakage.
6. Valve spool spring weakened or damaged.
11 Abnormal movement to the 1. Clutch defect, clutch disk and plate damaged.
specified direction at neutral
2. Valve spool defect or spool sticked.
3-43
(2) ABNORMAL NOISE CHECK LIST
No Problem Cause
1 Noise only at neutral 1. Gear or bearing wear inside the pump.

2.Torque converter stator wear.
3. Low oil level.
4. Gear parts of engine and T/M pump's misalignment with that of
converter housing and pump.
2 Pump noise 1. Loud noise irregularly repeats if there's contaminants in the T/M
hydraulic components.
2. Regular noise means pump defect.
3 T/M noise 1. Converter housing and pump gear misalignment with engine or T/M
2. T/M components wear or damage.
1) Gear damage.
2) Clutch plate and disk slip noise.
3) Thrust washer defect.
4) Another components wear or damage.
4 Control valve noise 1. Air mixed into hydraulic system.

1) Air leakage from the pump input port.
2. Clogged oil passage.
3. Abnormal spool movement.
3-44
(3) PRESSURE TEST CHECK LIST
No Problem Cause
1 FR/RR clutch low pressure Incorrect adjustment of inching valve linkage

Inching spool sticked and open.
Clutch and piston oil leakage.
Regulator spring defect.
Low oil pressure.
Incorrect connection of cooler external line.
2 High clutch and main pressure Pressure regulation valve does not move smoothly.
Clogged hydraulic line.
3 Low clutch pressure Oil leakage due to incorrect assembly of clutch piston seal.
Damage or wear of clutch piston seal and shaft seal.
Valve contact surface not flat or gasket damage.
4 Low main pressure Low oil quantity
Pressure regulation valve does not move smoothly.
Pump wear
Internal leakage
Low oil pressure
5 High converter pressure Main regulation valve sticked and open, oil overflow to converter.
Clogged internal passage of converter assembly.
Clogged oil line.
6 Low converter pressure Clogged main regulator valve.
7 Low converter output pressure, Low oil pressure
cooler input pressure.
Cooler bypass valve sticked and open.
8 High converter output pressure,
cooler input pressure Clogged or restricted cooler line.
3-45
(4) Transmission fault codes
Fault code Meaning of the fault code

(Hex) possible reason for fault detection Reaction of the TCU Possible steps to repair
11 Logical error at gear range signal TCU shifts transmission to Â Check the cables from TCU to
TCU detected a wrong signal combination neutral shift lever
for the gear range OP-mode : Transmission Â Check signal combinations of shift
ÂCable from shift lever to TCU is broken shutdown lever positions for gear range
ÂCable is defective and is contacted to ö Failure cannot be detected in
battery voltage or vehicle ground systems with DW2/DW3 shift lever.
ÂShift lever is defective Fault is taken back if TCU detects
a valid signal for the position
12 Logical error at direction select signal TCU shifts transmission to Â Check the cables from TCU to
TCU detected a wrong signal combination neutral shift lever
for the direction OP-Mode : Transmission Â Check signal combinations of shift
ÂCable from shift lever to TCU is broken shutdown lever positions F-N-R
ÂCable is defective and is contacted to ö Fault is taken back if TCU detects
battery voltage or vehicle ground a valid signal for the direction at
ÂShift lever is defective the shift lever
25 S .C. to battery voltage or O.C. at No reaction, TCU use Â Check the cable from TCU to the
transmission sump temperature sensor default temperature sensor
input OP mode : Normal Â Check the connectors
The measured voltage is too high: Â Check the temperature sensor
ÂCable is defective and is contacted to
battery voltage
ÂCable has no connection to TCU
ÂTemperature sensor has an internal
defect
ÂConnector pin is contacted to battery
voltage or is broken
26 S .C. to ground at transmission sump No reaction, TCU uses Â Check the cable from TCU to the
temperature sensor input default temperature sensor
The measured voltage is too low: OP mode : Normal Â Check the connectors
ÂCable is defective and is contacted to Â Check the temperature sensor
vehicle ground
defect
ÂConnector pin is contacted to vehicle
ground
27 S .C. to battery voltage or O.C. at No reaction, TCU uses Â Check the cable from TCU to the
retarder/torque converter temperature default temperature sensor
sensor input OP mode : Normal Â Check the connectors
The measured voltage is too high: Â Check the temperature sensor
battery voltage
defect
voltage or is broken
3-46
28 S.C. to ground at retarder/torque No reaction, TCU uses Â Check the cable from TCU to the
converter temperature sensor input default temperature sensor
The measured voltage is too low: OP mode : Normal Â Check the connectors
ÂCable is defective and is contacted to Â Check the temperature sensor
vehicle ground
defect
ÂConnector pin is contacted to vehicle
ground
2B I nch sensor-signal mismatch the During inching mode : TCU Â Check the cable from TCU to the
measured voltage from CCO and CCO2 shifts to neutral sensor
signal don't match : While not inching : no Â Check the connectors
ÂCable is defective change Â Check the sensor
ÂSensor has an internal defect OP-Mode : normal
31 S.C. to battery voltage or O.C. at engine OP mode : Substitute clutch Â Check the cable from TCU to the
speed input control sensor
TCU measures a voltage higher than Â Check the connectors
7.00V at speed input pin Â Check the speed sensor
battery voltage
ÂSpeed sensor has an internal defect
voltage or has no contact
32 S.C. to ground at engine speed input OP mode : Substitute clutch Â Check the cable from TCU to the
TCU measures a voltage less than 0.45V at control sensor
speed input pin Â Check the connectors
ÂCable/connector is defective and is Â Check the speed sensor
contacted to vehicle ground
33 Logical error at engine speed input OP mode : Substitute clutch Â Check the cable from TCU to the
TCU measures a engine speed over a control sensor
threshold and the next moment the Â Check the connectors
measured speed is zero Â Check the speed sensor
ÂCable/connector is defective and has Â Check the sensor gap
bad contact ö This fault is reset after power up of
ÂSpeed sensor has an internal defect TCU
ÂSensor gap has the wrong size
34 S.C. to battery voltage or O.C. at turbine OP mode : Substitute clutch Â Check the cable from TCU to the
speed input control sensor
TCU measures a voltage higher than If a failure is existing at Â Check the connectors
7.00V at speed input pin output speed, Â Check the speed sensor
ÂCable is defective and is contacted to TCU shifts to neutral
vehicle battery voltage OP mode : Limp home
3-47
35 S.C. to ground at turbine speed input OP mode : Substitute clutch Â Check the cable from TCU to the
TCU measures a voltage less than 0.45V control sensor
at speed input pin If a failure is existing at Â Check the connectors
ÂCable/connector is defective and is output speed, Â Check the speed sensor
contacted to vehicle ground TCU shifts to neutral ö This fault is reset after power up of
ÂSpeed sensor has an internal defect OP mode : Limp home TCU
36 Logical error at turbine speed input OP mode : Substitute clutch Â Check the cable from TCU to the
TCU measures a turbine speed over a control sensor
threshold and at the next moment the If a failure is existing at Â Check the connectors
measured speed is zero output speed, Â Check the speed sensor
ÂCable/connector is defective and has TCU shifts to neutral Â Check the sensor gap
bad contact OP mode : Limp home
37 S .C. to battery voltage or O.C. at OP mode : Substitute clutch Â Check the cable from TCU to the
internal speed input control sensor
TCU measures a voltage higher than Â Check the connectors
7.00V at speed input pin Â Check the speed sensor
vehicle battery voltage
38 S.C. to ground at internal speed input OP mode : Substitute clutch Â Check the cable from TCU to the
TCU measures a voltage less than 0.45V control sensor
at speed input pin Â Check the connectors
ÂCable/connector is defective and is Â Check the speed sensor
39 Logical error at internal speed input OP mode : Substitute clutch Â Check the cable from TCU to the
TCU measures a internal speed over a control sensor
threshold and at the next moment the Â Check the connectors
measured speed is zero Â Check the speed sensor
ÂCable/connector is defective and has Â Check the sensor gap
bad contact ö This fault is reset after power up of
ÂSpeed sensor has an internal defect TCU
3A S.C. to battery voltage or O.C. at output Special mode for gear Â Check the cable from TCU to the
speed input selection sensor
TCU measures a voltage higher than OP mode : S u b s t i t u t e Â Check the connectors
12.5V at speed input pin clutch control Â Check the speed sensor
ÂCable is defective and is contacted to If a failure is existing at
battery voltage turbine speed,
ÂCable has no connection to TCU TCU shifts to neutral
ÂSpeed sensor has an internal defect OP mode : lamp home
3-48
3B S.C. to ground at output speed input Special mode for gear Â Check the cable from TCU to the
TCU measures a voltage less than 1.00V selection sensor
at speed input pin OP mode : Substitute clutch Â Check the connectors
ÂCable/connector is defective and is control Â Check the speed sensor
contacted to vehicle ground If a failure is existing at
ÂSpeed sensor has an internal defect turbine speed,
TCU shifts to neutral
OP mode : lamp home
3C Logical error at output speed input Special mode for gear Â Check the cable from TCU to the
TCU measures a turbine speed over a selection sensor
threshold and at the next moment the OP mode : Substitute clutch Â Check the connectors
measured speed is zero control Â Check the speed sensor
ÂCable/connector is defective and has If a failure is existing at Â Check the sensor gap
bad contact turbine speed, ö This fault is reset after power up of
ÂSpeed sensor has an internal defect TCU shifts to neutral TCU
ÂSensor gap has the wrong size OP mode : lamp home
3E Output speed zero doesn't fit to other Special mode for gear Â Check the sensor signal of output
speed signals selection speed sensor
If transmission is not neutral and the OP mode : Substitute clutch Â Check the sensor gap of output
shifting has finished, control speed sensor
TCU measures output speed zero and If a failure is existing at Â Check the cable from TCU to the
turbine speed or internal speed not equal turbine speed, sensor
to zero. TCU shifts to neutral ö This fault is reset after power up of
ÂSpeed sensor has an internal defect OP mode : lamp home TCU
54 Vehicle1 timeout TCU shifts to neutral Â Check vehicle controller
Time of CAN-message Vehicle1 from NN(because of shifting Â Check wire of CAN-Bus
display computer lever) Â Check cable to vehicle controller
ÂInterference on CAN-Bus
ÂCAN wire/connector is broken
ÂCAN wire/connector is defective and has
contact to vehicle ground or battery
voltage
57 EEC1 timeout OP-Mode : substitute Â Check EEC controller
Timeout of CAN-message EEC1 from clutch control Â Check wire of CAN-Bus
EEC controller Â Check cable to EEC controller
ÂInterference on CAN-Bus
ÂCAN wire/connector is broken
ÂCAN wire/connector is defective and has
contact to vehicle ground or battery
voltage
71 S.C. to battery voltage at clutch KC TCU shifts to neutral Â Check the cable from TCU to the
The measured resistance value of the valve OP mode : Limp home gearbox
is out of limit, the voltage at KC valve is too If failure at another clutch Â Check the connectors from TCU to
high is pending the gearbox
ÂCable/connector is defective and has TCU shifts to neutral Â Check the regulator resistance*
contact to battery voltage OP mode : TCU shutdown Â Check internal wire harness of the
ÂRegulator has an internal defect gearbox
* See page 3-56
3-49
72 S.C. to ground at clutch KC TCU shifts to neutral Â Check the cable from TCU to the
is out of limit, the voltage at KC valve is too If failure at another clutch Â Check the connectors from
low is pending gearbox to TCU
contact to vehicle ground OP mode : TCU shutdown Â Check internal wire harness of the
ÂCable/connector is defective and has gearbox
contact to another regulator output of the * See page 3-56
TCU
ÂRegulator has an internal defect
73 O.C. at clutch KC TCU shifts to neutral Â Check the cable from TCU to the
The measured resistance value of the OP mode : Limp home gearbox
valve is out of limit If failure at another clutch Â Check the connectors from
ÂCable/connector is defective and has no is pending gearbox to TCU
contact to TCU TCU shifts to neutral Â Check the regulator resistance*
ÂRegulator has an internal defect OP mode : TCU shutdown Â Check internal wire harness of the
gearbox
* See page 3-56
74 S.C. to battery voltage at clutch KD TCU shifts to neutral Â Check the cable from TCU to the
valve is out of limit, the voltage at KD valve If failure at another clutch Â Check the connectors from
is too high is pending gearbox to TCU
* See page 3-56
75 S.C. to ground at clutch KD TCU shifts to neutral Â Check the cable from TCU to the
is out of limit, the voltage at KD valve is too If failure at another clutch Â Check the connectors from
TCU
76 O.C. at clutch KD TCU shifts to neutral Â Check the cable from TCU to the
gearbox
* See page 3-56
77 S.C. to battery voltage at clutch KE TCU shifts to neutral Â Check the cable from TCU to the
valve is out of limit, the voltage at KE valve If failure at another clutch Â Check the connectors from
* See page 3-56
3-50
78 S.C. to ground at clutch KE TCU shifts to neutral Â Check the cable from TCU to the
is out of limit, the voltage at KE valve is too If failure at another clutch Â Check the connectors from
TCU
79 O.C. at clutch KE TCU shifts to neutral Â Check the cable from TCU to the
gearbox
* See page 3-56
84 S.C. to battery voltage at clutch KV TCU shifts to neutral Â Check the cable from TCU to the
valve is out of limit, the voltage at KV valve If failure at another clutch Â Check the connectors from
* See page 3-56
85 S.C. to ground at clutch KV TCU shifts to neutral Â Check the cable from TCU to the
is out of limit, the voltage at KV valve is too If failure at another clutch Â Check the connectors from
TCU
86 O.C. at clutch KV TCU shifts to neutral Â Check the cable from TCU to the
ÂCable/connector is defective and has is pending gearbox to TCU
gearbox
* See page 3-56
87 S.C. to battery voltage at clutch KR TCU shifts to neutral Â Check the cable from TCU to the
valve is out of limit, the voltage at KR valve is If failure at another clutch Â Check the connectors from
too high is pending gearbox to TCU
* See page 3-56
3-51
88 S.C. to ground at clutch KR TCU shifts to neutral Â Check the cable from TCU to the
is out of limit, the voltage at KR valve is too If failure at another clutch Â Check the connectors from
TCU
89 O.C. at clutch KR TCU shifts to neutral Â Check the cable from TCU to the
gearbox
* See page 3-56
B1 Slippage at clutch KC TCU shifts to neutral Check pressure at clutch KC
TCU calculates a differential speed at OP mode : Limp home Check main pressure in the system
closed clutch KC. If this calculated value If failure at another clutch Check sensor gap at internal speed
is out of range, TCU interprets this as is pending sensor
slipping clutch TCU shifts to neutral Check sensor gap at output speed
ÂLow pressure at clutch KC OP mode : TCU shutdown sensor
ÂLow main pressure Check signal at internal speed
ÂWrong signal at internal speed sensor sensor
ÂWrong signal at output speed sensor Check signal at output speed sensor
ÂWrong size of the sensor gap Replace clutch
ÂClutch is defective
B2 Slippage at clutch KD TCU shifts to neutral Check pressure at clutch KD
TCU calculates a differential speed at OP mode : Limp home Check main pressure in the system
closed clutch KD. If this calculated value If failure at another clutch Check sensor gap at internal speed
is out of range, TCU interprets this as is pending sensor
slipping clutch TCU shifts to neutral Check sensor gap at output speed
ÂLow pressure at clutch KD OP mode : TCU shutdown sensor
ÂLow main pressure Check signal at internal speed
ÂWrong signal at internal speed sensor sensor
ÂWrong signal at output speed sensor Check signal at output speed sensor
ÂWrong size of the sensor gap Replace clutch
ÂClutch is defective
3-52
B3 Slippage at clutch KE TCU shifts to neutral Â Check pressure at clutch KE

TCU calculates a differential speed at OP mode : Limp home Â Check main pressure in the
closed clutch KE. If this calculated value If failure at another clutch system
is out of range, TCU interprets this as is pending Â Check sensor gap at internal
slipping clutch TCU shifts to neutral speed sensor
ÂLow pressure at clutch KE OP mode : TCU shutdown Â Check sensor gap at output speed
ÂLow main pressure sensor
ÂWrong signal at internal speed sensor Â Check signal at internal speed
ÂWrong signal at output speed sensor sensor
ÂWrong size of the sensor gap Â Check signal at output speed
ÂClutch is defective sensor
Â Replace clutch
B5 Slippage at clutch KV TCU shifts to neutral Â Check pressure at clutch KV
closed clutch KV. If this calculated value If failure at another clutch system
ÂLow pressure at clutch KV OP mode : TCU shutdown Â Check sensor gap at turbine
ÂLow main pressure speed sensor
ÂWrong signal at turbine speed sensor sensor
ÂWrong size of the sensor gap Â Check signal at turbine speed
Â Replace clutch
B6 Slippage at clutch KR TCU shifts to neutral Â Check pressure at clutch KR
closed clutch KR. If this calculated value If failure at another clutch system
ÂLow pressure at clutch KR OP mode : TCU shutdown Â Check sensor gap at turbine
ÂLow main pressure speed sensor
ÂWrong signal at turbine speed sensor sensor
ÂWrong size of the sensor gap Â Check signal at turbine speed
Â Replace clutch
B7 Overtemp sump No reaction Â Cool down machine
TCU measured a temperature in the oil OP mode : Normal Â Check oil level
sump that is over the allowed threshold. Â Check temperature sensor
B8 Overtemp converter No reaction Â Cool down machine
TCU measured a temperature in the OP mode : Normal Â Check oil level
retarder oil that is over the allowed Â Check temperature sensor
threshold
B9 Overspend engine Retarder applies
-
OP mode : Normal
BC Overtemp converter No reaction
TCU measured a transmission output OP mode : Normal
speed above the define threshold
C0 Engine torque or engine power overload OP mode : Normal

TCU calculates an engine torque or engine
power above the defined thresholds
3-53
C1 Transmission output torque overload OP mode : Normal

TCU calculates an transmission output
torque above the defined threshold
C2 Transmission input torque overload programmable : No
TCU calculates an transmission output reaction or shift to neutral
torque above the defined threshold OP mode : Normal
C3 Overtemp converter output No reaction Â Cool down machine
TCU measured a oil temperature at the OP mode : Normal Â Check oil level
converter output that is the allowed Â Check temperature sensor
threshold
D1 S.C. to battery voltage at power supply See fault codes No.21 to Check cables and connectors to
for sensors 2C sensors, which are supplied from
TCU measures more than 6V at the pin AU1
AU1 (5V sensor supply) Check the power supply at the pin
AU1(Should be appx. 5V)
Fault codes No.21 to No.2C may be
reaction of this fault
D2 S.C. to ground at power supply for See fault codes No.21 to Check cables and connectors to
sensors 2C sensors, which are supplied from
TCU measures less than 4V at the pin AU1
AU1 (5V sensor supply) Check the power supply at the pin
AU1(Should be appx. 5V)
Fault codes No.21 to No.2C may be
reaction of this fault
D3 Low voltage at battery Shift to neutral Check power supply battery
Measured voltage at power supply is lower OP mode : TCU shutdown Check cables from batteries to TCU
than 18V(24V device) Check connectors from batteries to
TCU
D4 High voltage at battery Shift to neutral Check power supply battery
Measured voltage at power supply is OP mode : TCU shutdown Check cables from batteries to TCU
higher than 32.5V(24V device) Check connectors from batteries to
TCU
D5 Error at valve power supply VPS1 Shift to neutral Check fuse
TCU switched on VPS1 and measured OP mode : TCU shutdown Check cables from gearbox to TCU
VPS1 is off or TCU switched off VPS1 and Check connectors from gearbox to
measured VPS1 is still on TCU
ÂCable or connectors are defect and are Replace TCU
contacted to battery voltage
ÂCable or connectors are defect and are
ÂPermanent power supply KL30 missing
ÂTCU has an internal defect
D6 Error at valve power supply VPS2 Shift to neutral Check fuse
TCU switched on VPS2 and measured OP mode : TCU shutdown Check cables from gearbox to TCU
VPS2 is off or TCU switched off VPS2 and Check connectors from gearbox to
measured VPS2 is still on TCU
ÂCable or connectors are defect and are Replace TCU
contacted to battery voltage
ÂCable or connectors are defect and are
ÂPermanent power supply KL30 missing
ÂTCU has an internal defect
3-54
E3 S.C. to battery voltage at display output No reaction Â Check the cable from TCU to the
TCU sends data to the display and OP mode : Normal display
measures always a high voltage level on Â Check the connectors at the
the connector display
ÂCable or connectors are defective and Â Change display
are contacted to battery voltage
ÂDisplay has an internal defect
E4 S.C. to ground at display output No reaction Â Check the cable from TCU to the
TCU sends data to the display and OP mode : Normal display
measures always a high voltage level on Â Check the connectors at the
the connector display
ÂCable or connectors are defective and Â Change display
are contacted to battery voltage
ÂDisplay has an internal defect
F1 General EEPROM fault No reaction Â Replace TCU
TCU can't read non volatile memory OP mode : Normal ö Often shown together with fault
ÂTCU is defective code F2
F2 Configuration lost Transmission stay neutral Â Reprogram the correct configurat-
TCU has lost the correct configuration and OP mode : TCU shutdown ion for the vehicle (e.g. with cluster
can't control the transmission controller,...)
ÂInterference during saving data on non
volatile memory
ÂTCU is brand new or from another
vehicle
F3 Application error Transmission stay neutral Â Replace TCU
Something of this application is wrong OP mode : TCU shutdown ö This fault occurs only if an test
engineer did something wrong in
the application of the vehicle
F5 Clutch failure Transmission stay neutral Â Check clutch
AEB was not able to adjust clutch filling OP mode : TCU shutdown ö TCU shows also the affected
parameters clutch on the display
ÂOne of the AEB-Values is out of limit
F6 Clutch adjustment data lost or Inch No reaction, Â Execute AEB
pedal calibration data lost Default values : 0 for AEB
TCU was not able to read correct clutch Offsets used
adjustment parameters OP mode : Normal
ÂInterference during saving data on non
volatile memory
ÂTCU is brand new
3-55
(5) Measuring of resistance at actuator/sensor and cable
Η Actuator
2 G
76043PT19
Open circuit R12 = R1G = R2G = â

Short cut to ground R12 = R; R1G = 0, R2G = R or R1G = R, R2G = 0
(For S.C. to ground, G is connected to vehicle ground)
Short cut to battery R12 = R; R1G = 0, R2G = R or R1G = R, R2G = 0
(For S.C. to battery, G is connected to battery voltage)
Θ Cable
UBat
P(Power supply)
TCU
1 2 Actuator/
Sensor
C(Chassis)
Ground
76043PT20
Open circuit R12 = R1P = R1C = R2P = R2C= â

Short cut to ground R12 = 0; R1C = R2C = 0, R1P = R2P = â
Short cut to battery R12 = 0; R1C = R2C = 0, R1P = R2P = 0
3-56
GROUP 3 DISASSEMBLY AND ASSEMBLY
1. TRANSMISSION DISASSEMBLY
1) DISASSEMBLY
Transmission 3 WG-94 EC
50DS7ETM11
Η Attach transmission to the assembly truck

by means of clamping angles(1) and
holding fixtures(2).
(S) Assembly truck 5870 350 000
(S) Holding fixtures 5870 350 063
(S) Clamping angles 5870 350 124 2 2
1 1
50DS7ETM12
(1) Removal of the filter

ö Drain oil prior to starting disassembly.
Η Remove screw plug(1).
Disposal of oil according to legal
requirements.
1
50DS7ETM13
Θ Loosen the cylindrical screws(1) and

remove the oil filler tube with the oil
dipstick(2).
2
ö Remove the O-ring(3) from the oil filler
tube.
3
1
50DS7ETM14
3-57
Ι Separate the fine filter(1) from the filter
head by means of belt wrench.
(S) Belt wrench 5870 105 005
50DS7ETM15
Κ Loosen the cylindrical screws(2) and

separate the filter head(1) from the
2
transmission housing.
50DS7ETM16
Λ Remove both O-rings(1) out of the

annular groove of the filter head.
1
50DS7ETM17
3-58
2) DISASSEMBLY PRESSURE CONTROLLER
(PROPORTIONAL VALVES), INDUCTIVE
SENSOR, SPEED SENSOR(HALL SENSOR),
TEMPERATURE SENSOR, BREATHER
AND SCREW PLUGS
Η Remove all screw plugs with O-ring(1
and 2).
1
2
50DS7ETM18
Θ Loosen cylindrical screws(1) and remove

pressure controller(proportional valves,
2
2).
50DS7ETM19
Ι Remove positioned parts. 4 3

1 = Inductive sensor-n turbine
2 = Inductive sensor-n central gear chain
3 = Temperature sensor, measuring point
1
"63" after converter
4 = Inductive sensor 2
ö Remove O-rings.
50DS7ETM20
3-59
Κ Loosen cylindrical screw(1) and remove
speed sensor(2).
2 = Speed sensor-n output(Hall sensor)
ö Remove O-rings.
2
1
50DS7ETM21
Λ Remove breather (1).

1
50DS7ETM22
3-60
3) DISASSEMBLY CONVERTER AND 1
CENTRAL SHAFT(PTO SHAFT) 2
Η Loosen cylindrical screws(1) and
separate the flexplate(2) from the
converter(3). 3
50DS7ETM23
Θ Pull off converter(1) by hand.
50DS7ETM24
Ι Disengage the retaining ring(see arrow).
50DS7ETM25
Κ Pull the central shaft assy out of the

housing hole.
1 = Central shaft 3 1
2 = Retaining ring 4
3 = Ball bearing
4 = Toothed disk
2
50DS7ETM26
3-61
Λ Pull the toothed disk(1) from the central
shaft.
50DS7ETM27
Μ Press the ball bearing(1) from the central

shaft(2).
50DS7ETM28
3-62
4) DISASSEMBLY OF OUTPUT FLANGE
Η Loosen the hexagon screws(1) and
remove disk and O-ring(2 and 3). 3
1
2
50DS7ETM29
Θ Pull output flange(1) off the output shaft

by means of two-armed puller.
50DS7ETM30
Ι Remove shaft seal(see arrow) from the

housing hole by means of assembly
lever.
50DS7ETM31
3-63
5) DISASSEMBLY OF MAIN PRESSURE
VALVE AND CONVERTER SAFETY VALVE
Η Loosen screw plug(1) and remove main
pressure valve(control pressure valve): 4
Main pressure valve consists of: 2

1
1 = Screw plug with O-ring
2 = Piston
3
3 = Spacer rings
4 = Compression spring 50DS7ETM32
Θ Loosen screw plug(1) and remove

converter safety valve.
Converter safety valve consists of :
1 = Screw plug with O-ring 2
2 = Pressure valves 1
- = Valve assy is installed in the housing-
not visible-(functional check of valve
see below Ι).
50DS7ETM33
Ι Functional check of valve.

ö Use a screwdriver to check the
movability of the ball in the valve.
If the valve is o.k., it does not need to be
removed.
50DS7ETM34
3-64
6) REMOVAL OF CLUTCHES AND 1
2 1
DISASSEMBLY OF OIL PRESSURE PUMP
Η Force out cylindrical pins(1).
Θ Loosen bolted connection(2) of housing
front and rear part.
Make sure to leave 2 cylindrical screws
crosswise in the bolted connection(2).
Transmission rear part is not fixed to
the clamping angle and could get 50DS7ETM35
loose when turning.
Ι Rotate transmission housing 180ä,

loosen the last 2 cylindrical screws from
the bolted connection housing front and
rear part and separate housing rear part
by means of lifting device.
ö Support by means of assembly lever.
(S) Assembly lever 5870 345 036
50DS7ETM36
Κ Lift the clutches out of the housing in the

4 6
following sequence: 3
1 5
1 = Clutch KE (Clutch-3rd gear) 2
2 = Clutch KV (Clutch-forward)
3 = Clutch KR (Clutch-reverse and input)
4 = Clutch KD (Clutch-2nd gear)
5 = Clutch KC (Clutch-1st gear)
6 = Output with screen sheet
50DS7ETM37
3-65
Λ Use assembly lever to remove all bearing
outer rings from the housing front part.
ö If, contrary to the ZF recommendation,
the tapered roller bearings of clutches
and output are not replaced, it is
imperative to ensure the previous pair-
ing(bearing outer ring/bearing inner
ring).
ö Bearing outer ring and bearing inner
50DS7ETM38
ring must be marked.
Μ Use assembly lever to remove all bearing

outer rings from the housing rear part.
1
and output are not replaced, it is
imperative to ensure the previous pair-
ing(bearing outer ring/bearing inner
ring).
ö Bearing outer ring and bearing inner
50DS7ETM39
ring must be marked.
Ν Remove O-ring(1).
Ξ Loosen cylindrical screws(1) and remove

2
suction tube(2).
50DS7ETM40
Ο Loosen cylindrical screws (1).
50DS7ETM41
3-66
Π Loosen bolted connection between
1
converter bellhousing/transmission
housing(1) and pressure oil pump/ 2
transmission housing(2).
50DS7ETM42
Ρ Press converter bellhousing off the

housing equally by means of hexagon 1
screws M10(1).
ö Difficult disassembly due to fixing by
cylindrical pins.
50DS7ETM43
΢ If required, remove both cylindrical pins

1
(1).
50DS7ETM44
Σ Remove oil pressure pump(1).
50DS7ETM45
3-67
Τ Remove filter(1).
1
50DS7ETM46
Υ Remove O-ring(1).
Loosen cylindrical screws(2).
1
2
50DS7ETM47
ö Check oil pressure pump :

In case of wear marks in the pump
housing, stator hollow shaft or on the 1
inner and outer rotor, the
complete oil pressure pump is to be 2
replaced.
3
1 = Stator hollow shaft
2 = Inner rotor 4
3 = Outer rotor
4 = Pump housing 50DS7ETM48
Remove shaft seal(1) from the pump

housing(2).
50DS7ETM49
3-68
7) DISASSEMBLY CLUTCHES :
5 6
3 4
1 = Clutch KV(Clutch-forward) 2
2 = Clutch KR(Clutch-reverse and input) 1
3 = Clutch KD(Clutch-2nd gear)
4 = Clutch KE(Clutch-3rd gear)
5 = Clutch KC(Clutch-1st gear)
6 = Output
50DS7ETM50
(1) Clutch KR/input

Η Disengage rectangular ring(1).
50DS7ETM51
Θ Pull off bearing inner ring with inner disk

carrier(1).
50DS7ETM52
Ι Remove bearing inner ring(1), axial

1
bearing assy(2) and inner disk carrier (3).
2
50DS7ETM53
3-69
Κ Remove needle cage(1).
1
50DS7ETM54
Λ Remove axial bearing assy(1).

1
50DS7ETM55
Μ Disengage snap ring(1).
50DS7ETM56
Ν Remove end plate(1), disk package(2)

and plate with cup springs(3) from the
disk carrier.
3
2
1
50DS7ETM57
3-70
Ξ Remove retaining ring-contact position of 1
axial bearing(1).
50DS7ETM58
Ο Preload compression spring and

disengage retaining ring(1).
(S) Assembly aid 5870 345 114
50DS7ETM59
Π Remove cup spring(1) and compression

1
spring(2).
2
50DS7ETM60
Ρ By means of compressed air(see arrow),

1
press piston(1) off the shaft/disk carrier
(see arrow) and remove it.
50DS7ETM61
3-71
΢ Remove both O-rings(1 and 2).
50DS7ETM62
Σ Disengage rectangular rings(1).

1
50DS7ETM63
Τ Pull tapered roller bearing(inner ring) off

the shaft.
(S) Grab sleeve 5873 001 026
(S) Basic tool 5873 001 000
50DS7ETM64
ö The clutch(1) cannot be disassembled.

It is supplied by the spare par ts 1A
service only as a complete assy which 1B
consists of :
1C
1A = Ball 1
1B = Helical gear 1D
1C = Disk carrier
1D = Input shaft
50DS7ETM65
3-72
(2) Clutch KV
1
Η Snap out rectangular ring(1).
50DS7ETM66

carrier(1).
50DS7ETM67
Ι Remove bearing inner ring(1), axial

1
bearing assy(2) and inner disk carrier(3).
2
50DS7ETM68

1
50DS7ETM69
3-73
1
50DS7ETM70
Μ Remove snap ring(1).

1
50DS7ETM71

and plate(3) from the disk carrier.
1
50DS7ETM72
Ξ Remove retaining ring-contact position of

1
axial bearing(1).
50DS7ETM73
3-74
Ο Preload compression spring and remove
retaining ring(1).
1
50DS7ETM74
Π Remove cup spring(1) and compression

1
spring(2).
2
50DS7ETM75

press piston(1) off the shaft/disk carrier 1
and remove it.
50DS7ETM76
50DS7ETM62
3-75
Σ Snap out rectangular ring(1).
50DS7ETM78

the shaft.
(S) Grab sleeve 5873 000 029
(S) Basic tool 5873 000 000
50DS7ETM79

It is supplied by the spare parts ser- 1A
vice only as a complete assy which
1B
consists of :
1A = Retaining ring 1C 1
1B = Helical gear
1C = Disk carrier
1D = Shaft 1D
50DS7ETM80
3-76
(3) Clutch KD
1
50DS7ETM81
Θ Pull tapered roller bearing(inner ring) off

the shaft.
(S) Grab sleeve 5873 000 029
(S) Basic tool 5873 000 000
50DS7ETM82
Ι Remove axial bearing assy(1) and inner

disk carrier.
1
50DS7ETM83
50DS7ETM84
3-77
50DS7ETM85
Μ Remove snap ring(1).
50DS7ETM86

and cup spring(3) from the disk carrier.
1
50DS7ETM87
Ξ Remove retaining ring-contact position of

axial bearing(1). 1
50DS7ETM88
3-78
Ο Preload compression spring and remove
snap ring(1).
50DS7ETM89
Π Remove spring cup(1) and compression

spring(2). 1
50DS7ETM90

press piston(1) off the shaft/disk carrier
and remove it. 1
50DS7ETM91
50DS7ETM62
3-79
Σ Snap out rectangular ring(1).
1
50DS7ETM93

the shaft.
(S) Rapid grip 5873 011 011
(S) Extractor set 5870 026 100
50DS7ETM94

consists of : 1B
1
1A = Retaining ring 1C
1B = Helical gear
1C = Disk carrier
1D = Shaft 1D
50DS7ETM95
3-80
(4) Clutch KE
1
50DS7ETM96
Θ Pull tapered roller bearing(inner ring) off

the shaft.
(S) Grab sleeve 5873 000 029
(S) Basic tool 5873 001 000
50DS7ETM97
Ι Remove retaining ring(1).

1
50DS7ETM98
Κ Remove bearing inner ring(1) and inner

disk carrier(2).
50DS7ETM99
3-81
Λ Remove tapered roller bearing(1) and
1
inner disk carrier(2).
2
50DS7ETM100
Μ Pull off bearing inner ring(1) and running

disk(2).
1 2
50DS7ETM101
Ν Remove bearing inner ring(1) and

running disk(2). 1
2
50DS7ETM102
Ξ Disengage snap ring(1).

1
50DS7ETM103
3-82
Ο Remove end plate(1), disk package(2)
and cup spring(3) from the disk carrier.
1
50DS7ETM104
Π Preload compression spring and remove

snap ring(1).
1
50DS7ETM105
Ρ Remove spring cup(1) and compression

spring(2). 1
50DS7ETM106
΢ By means of compressed air(see arrow),

and remove it.
50DS7ETM107
3-83
Σ Remove both O-rings(1 and 2).
50DS7ETM62
Τ Snap out rectangular ring(1).

1
50DS7ETM109
Υ Pull tapered roller bearing(inner ring) off

the shaft.
(S) Rapid grip 5873 011 011
(S) Basic tool 5873 001 000
50DS7ETM110

It is supplied by the spare parts ser-
1A
consists of : 1B
1
1A = Retaining ring
1B = Helical gears 1C
1C = Disk carrier
1D = Shaft 1D
50DS7ETM111
3-84
(5) Clutch KC
1
50DS7ETM112

carrier(1).
50DS7ETM113
Ι Remove bearing inner ring(1), axial 1

bearing assy(2) and inner disk carrier (3).
2
50DS7ETM114
Κ Remove needle cage(1) and bush(2).
1 2
50DS7ETM115
3-85
Λ Remove axial disk(1) and axial needle
1
cage(2).
2
50DS7ETM116
Μ Disengage snap ring(1).
50DS7ETM117
Ν Remove end plate(1) and disk package

(2) from the disk carrier.
1
50DS7ETM118
Ξ Preload compression springs and

remove snap ring(1).
(S) Assembly aid 5870 506 128 1
50DS7ETM119
3-86
Ο Remove disk(1) and cup springs(2). 1
50DS7ETM120
Π By means of compressed air(see arrow),

and remove it.
Remove both Orings.
50DS7ETM121
Ρ Snap out rectangular ring(1).

1
50DS7ETM122
΢ Pull tapered roller bearing(inner ring) off

the shaft.
(S) Grab sleeve 5873 002 029
(S) Basic tool 5873 000 001
50DS7ETM123
3-87
1B
consists of:
1A = Retaining ring 1C 1
1B = Helical gear
1C = Disk carrier 1D
1D = Shaft
50DS7ETM124
3-88
(6) Output shaft
Η Pull the bearing inner ring off the output
shaft.
(S) Grab sleeve 5873 000 029
(S) Basic tool 5873 000 001
50DS7ETM125
Θ Rotate output shaft 180äand pull off

bearing inner ring.
(S) Grab sleeve 5873 002 035
or
(S) Rapid grip 5873 012 011
(S) Basic tool 5873 002 000
50DS7ETM126
3-89
2. TRANSMISSION ASSEMBLY
1) REASSEMBLY OF CLUTCHES : 1A
1B
(1) Clutch KR/input
ö The clutch(1) is supplied by the spare 1C
1
parts service only as a complete assy
which consists of: 1D
1A = Ball
1B = Helical gear
1C = Disk carrier 50DS7ETM65
1D = Input shaft
Η Heat up bearing inner ring(approx.
120äC).
50DS7ETM128
Θ Mount bearing inner ring(1) until contact

2
is obtained. 1
Fit rectangular rings 50Ý2.5(2).

Wear protective gloves.
ö Adjust bearing inner ring after cooling-
down.
50DS7ETM129
Ι Insert both O-rings(1 and 2) into the piston

grooves and oil them.
1 = 40Ý3
1
2 = 104.5Ý3
2
50DS7ETM62
3-90
Κ Insert piston(1) into the disk carrier.
1
ö Pay attention to the installation
position, see Figure.
50DS7ETM131
Λ Use a hand-operated press to place

piston into the disk carrier by means of
the assembly aid.
50DS7ETM132
Μ Mount compression spring(1) and cup

spring(2). 2
1
50DS7ETM60
Ν By means of the assembly aid, preload

compression spring under a hand-
operated press until the retaining ring 40
Ý1.75(1) can be snapped in.
1
50DS7ETM59
3-91
Ξ Mount plate assy with cup springs(1),
with the open side showing towards the 1
piston(see arrow).
ö Installation position plate-see below
figure.
50DS7ETM135
Ο Fit plate(1) according to sketch(see

2 1
arrow).
1 = Plate with cup springs
2 = Compression spring with spring cup
and retaining ring 3
3 = Piston with Orings
4
4 = Clutch assy
50DS7ETM136
Π Install outer and inner disks alternately

into the disk carrier(3) as shown in figure.
Starting with an outer disk and ending
with an inner disk.
2 1
1 = Outer disks(10 pcs)
2 = Inner disks(10 pcs)
3 = Clutch assy
3
50DS7ETM137
Ρ Mount end plate(1) with the flat side

2
showing towards the disk package and fix
it by means of snap ring(2)(e.g.
thickness=2.5mm/recommended value).
ö Pay attention to the installation position 1
of the end plate.
50DS7ETM138
3-92
΢ Equally press on end plate with F
(approx. 100N = 10kg) and set dial
indicator to "zero". F
50DS7ETM139
Σ Then press end plate against the snap

ring(upwards) and read the disk F
clearance.
ö Disk clearance : 2.2 to 2.6mm
ö In case of deviations, the disk clear-
ance must be corrected with an appro-
priate snap ring(optional thickness =
2.0 ...... 3.5mm/available in steps of
0.25mm).
50DS7ETM140
Τ Snap retaining ring 40Ý1.75(1) into the

groove.
1
ö Contact for axial bearing - see below
figure.
50DS7ETM141
Υ Mount running disk 40Ý60Ý3.5(1), axial 3

needle cage 40Ý60Ý3(2) and axial 2
washer 40Ý60Ý1(3) and oil them. 1
ö Fit running disk(1), with the chamfer

showing towards the retaining ring.
50DS7ETM142
3-93
Mount needle cage 40Ý45Ý17(1) and
1
oil it.
50DS7ETM143
Mount inner disk carrier until contact is

obtained.
1
Install inner disks by short ccw/cw
rotations of the inner disk carrier(1).
L R
50DS7ETM144
Mount axial washer 40Ý60Ý1(1), axial 3

needle cage 40Ý60Ý3(2) and running 2
disk(3) 40Ý60Ý3.5 and oil them. 1
showing towards the tapered roller
bearing.
50DS7ETM145
Heat up bearing inner ring(approx.

120ä
C).
50DS7ETM128
3-94
Mount bearing inner ring(1) until contact
is obtained.
Fit rectangular ring 30Ý2(2).
Wear protective gloves. 2
1
ö Adjust bearing inner ring after cool-
ing-down.
50DS7ETM147
ö Check closing and opening of the

clutch by means of compressed air at
the hole(see arrow).
Closing and opening of the clutch must
be clearly audible.
50DS7ETM148
3-95
(2) Clutch KV
1A
The clutch(1) is supplied by the spare
parts service only as a complete assy 1B
which consists of :
1
1B = Helical gear
1C = Disk carrier
1D
1D = Shaft
50DS7ETM149

120ä
C).
50DS7ETM128

2
is obtained. 1
Fit rectangular rings 30Ý2(2).

ö Adjust bearing inner ring after cooling-down.
50DS7ETM151
Ι Insert both O-rings(1 and 2) into the

piston grooves and oil them.
1 = 40Ý3 1
2 = 104.5Ý3
2
50DS7ETM62
3-96
Κ Insert piston(1) into the disk carrier.
1
ö Pay attention to the installation posi-
tion, see figure.
50DS7ETM76

the assembly aid.
50DS7ETM154
Μ Mount compression spring(1) and spring

2
cup(2).
1
50DS7ETM75

1
50DS7ETM74
3-97
Ξ Mount plate assy with cup springs(1),
with the open side showing towards the 1
piston(see arrow).
ö Installation position plate-see below
figure.
50DS7ETM157
Ο Fit plate (1) according to sketch(see

arrow). 2 1
1 = Plate with cup springs

2 = Compression spring with cup spring
3 = Piston with O-rings
4 = Clutch assy 4
50DS7ETM158

with an inner disk.
2 1
2 = Inner disks(10 pcs) 3
3 = Clutch assy
50DS7ETM159

showing towards the disk package and fix 2
it by means of snap ring(2)(e.g.
1
ö Pay attention to the installation position
of the end plate.
50DS7ETM160
3-98
(approx. 100N = 10kg) and set dial F
indicator to "zero".
50DS7ETM161

clearance.
ö Disk clearance : 2.2 to 2.6mm
2.0~3.5mm/available in steps of
0.25mm).
50DS7ETM162
Τ Snap retaining ring 40Ý1.75(1) into the

groove.
1
ö Contact for axial bearing-see below
figure.
50DS7ETM163
Υ Mount running disk 40Ý60Ý3.5(1), axial 3

needle cage 40Ý60Ý3(2) and axial 2
washer 40Ý60Ý1(3) and oil them. 1
50DS7ETM164
3-99
oil it. 1
50DS7ETM69

obtained. 1
Install inner disks by short ccw/cw L R
50DS7ETM166
Mount axial washer 40Ý60Ý1(1), axial

3
bearing.
50DS7ETM167

120ä
C).
50DS7ETM128
3-100
2
is obtained.
1
50DS7ETM169

be clearly audible.
50DS7ETM170
3-101
(3) Clutch KD
ö The clutch(1) is supplied by the spare 1A
parts service only as a complete assy 1B
which consists of :
1
1B = Helical gear
1C = Disk carrier
1D
1D = Shaft
50DS7ETM95

120ä
C).
50DS7ETM128

is obtained. 2
1
50DS7ETM171
Ι Piston(1) with drain valve.

ö Check function of the drain valve (2). 1
There must be no jamming of the
ball(see arrow).
2
ö The piston(1) is supplied by the spare
parts service only as a complete assy.
50DS7ETM172
3-102
Κ Insert both O-rings(1 and 2) into the
1 = 40Ý3 1
2 = 104.5Ý3
2
50DS7ETM62
Λ Insert piston(1) into the disk carrier.

ö Pay attention to the installation position, 1
see figure.
50DS7ETM91
Μ Use a hand-operated press to place

the assembly aid.
50DS7ETM173
Ν Mount compression spring(1) and spring

cup(2). 1
50DS7ETM90
3-103
Ξ By means of the assembly aid, preload
1
50DS7ETM89
Ο Cup spring(1) into the disk carrier.

ö Pay attention to the installation position,
see next page TM177.
50DS7ETM174

with an inner disk.
2 1
3
2 = Inner disks(12 pcs)
3 = Clutch assy
50DS7ETM175

it by means of snap ring(2) (e.g.
thickness = 2.5mm/recommended value). 1

of the end plate, see next page
TM177.
50DS7ETM176
3-104
΢ Cap spring(1) according to sketch(see
arrow). 1 2 3 4
1 = Cup spring
and retaining ring
3 = Inner clutch- and outer clutch disc 5
4 = End shim
5 = Piston with O-rings 6
6 = Clutch assy.
50DS7ETM177
Σ Equally press on end plate with F

(approx. 100N = 10kg) and set dial
indicator to "zero". F
50DS7ETM178
Τ Then press end plate against the snap

ring(upwards) and read the disk
F
clearance.
ö Disk clearance : 2.6 to 3.1mm.
2.0~3.5mm/available in steps of
0.25mm).
50DS7ETM179
Υ Snap retaining ring 40Ý1.75(1) into the

groove.
ö Contact for axial bearing - see next 1
page TM181.
50DS7ETM180
3-105
Mount running disk 40Ý60Ý3.5(1), axial
3
needle cage 40Ý60Ý3(2) and axial
2
washer 40Ý60Ý1(3) and oil them.
1
50DS7ETM181

oil it. 1
50DS7ETM84

obtained. 1
Install inner disks by short ccw/cw

L R
50DS7ETM182
Mount axial washer 40Ý60Ý1(1), axial

3
needle cage 40Ý60Ý3(2) and running
2
bearing.
50DS7ETM183
3-106
120ä
C).
50DS7ETM128

is obtained. 2
1
ö Adjust bearing inner ring after
cooling-down.
50DS7ETM184

be clearly audible.
50DS7ETM185
3-107
(4) Clutch KE
1A
ö The clutch(1) is supplied by the spare
parts service only as a complete assy
1B
which consists of :
1
1A = Retaining ring
1C
1B = Helical gear
1C = Disk carrier
1D = Shaft 1D
50DS7ETM111

120ä
C).
50DS7ETM128

is obtained. 2
1
50DS7ETM186
Ι Piston(1) with drain valve.

1
ö Check function of the drain valve(2).
There must be no jamming of the
ball(see arrow). 2
ö The piston(1) is supplied by the spare
parts service only as a complete assy.
50DS7ETM187
3-108
Κ Insert both O-rings(1 and 2) into the
1 = 40Ý3 1
2 = 104.5Ý3
2
50DS7ETM62
50DS7ETM107

the assembly aid.
50DS7ETM188
Μ Mount compression spring(1) and spring

cup(2). 1
50DS7ETM106
3-109
1
50DS7ETM105
Ξ Cup spring(1) into the disk carrier.

1
tion, see next page TM192.
50DS7ETM189
Ο Install outer and inner disks alternately

with an inner disk.
2 1
3 = Clutch assy
50DS7ETM190
Π Mount end plate(1) with the flat side

it by means of snap ring(2) (e.g.
1
tion of the end plate, see next page
TM192.
50DS7ETM191
3-110
Ρ Cap spring(1) according to sketch(see
1 2 3 4
arrow).
1 = Cup spring
and retaining ring
3 = Inner clutch-and outer clutch disc 5
4 = End shim
6
6 = Clutch assy
50DS7ETM192

(approx. 100 N = 10kg) and set dial F
indicator to "zero".
50DS7ETM193

clearance.
priate snap ring(optional thick-
ness=2.0~3.5mm/available in steps of
0.25mm).
50DS7ETM194
Τ Mount running disk 35Ý52Ý3.5(1).

1
50DS7ETM195
3-111
Υ Press in both bearing outer rings into the
inner disk carrier(1) until contact is
obtained.
Then mount the bearing inner rings.
50DS7ETM196
ö Setting of axial play of the inner disk

carrier bearingÜ0.05mm(see TM197
to TM202) :
Determine dimension "X2" of the inner
disk carrier Ą see below figure.
Calculation example :
Dimension A ---------------------------- 97.00mm
Dimension B ------------------------- - 57.00mm
Dimension X2 ----------------------- = 40.00mm
50DS7ETM197
Legend :
1 = Inner disk carrier
1
2 = Tapered roller bearing 59Ý35Ý16
B A
3 = Tapered roller bearing 62Ý35Ý18
2
X2
3
50DS7ETM198
Mount the retaining ring e.g. 35Ý2.0(1)

and bring it into contact position by
means of a two-armed puller.
50DS7ETM199
3-112
Determine dimension "X1" from retaining
ring(1) to running disk(2).
Ą see below figure.
Dimension X1 = 42.1mm
1
50DS7ETM200
Legend : 1
1 = Retaining ring 35Ý2.0 2 X1
2 = Running disk 35Ý52Ý3.5
3
3 = Compression spring with cup spring
4 = Disk package with end plate and 5
snap ring
6
6 = Clutch assy 7
7 = Tapered roller bearing 50DS7ETM201
Axial play of inner disk carrier bearing

S
Ü0.05
Calculation example :
Dimension X1 ------------------------- 42.10mm X1 X2
Dimension X2 ----------------------- - 40.00mm
Dimension S(retaining ring) --- = 2.10mm
ö Determined retaining ring S = 2.10mm
ö Axial play must be set with the retaining
ring(optional thickness = 1.8~2.7mm/ 50DS7ETM202
available in steps of 0.10mm).

120äC).
50DS7ETM128
3-113
is obtained.
ö Different bearing sizes Ą see page 1
3-124 TM198.
ö Adjust bearing inner ring after
cooling-down.
50DS7ETM203

obtained.
rotations of the inner disk carrier(1). 1
50DS7ETM204

120äC).
50DS7ETM128

is obtained. 2
1
ö Adjust bearing inner ring after cool-
ing-down.
Snap in retaining ring 35Ý2.1(2).
ö Pay attention to an exact contact of the
retaining ring in the groove.
50DS7ETM205
3-114
120äC).
50DS7ETM128

is obtained. 2
1
50DS7ETM206

be clearly audible.
50DS7ETM207
3-115
(5) Clutch KC
ö The clutch(1) cannot be disassembled. 1A
It is supplied by the spare parts service 1B
only as a complete assy which consists of :
1
1B = Helical gear
1C = Disk carrier 1D
1D = Shaft
50DS7ETM124

120ä
C).
50DS7ETM128

is obtained. 2
1
50DS7ETM208
Ι Insert both O-rings(1 and 2) into the

1
piston(3) grooves and oil them.
2
1 = 115Ý3
3
2 = 52Ý3
Insert piston(3) into the disk carrier.
tion, see next page TM211.
ö Check function of the drain valve (see
50DS7ETM209
arrow) - There must be no jamming of
the ball.
3-116
Κ Use a hand-operated press to place
the assembly aid.
50DS7ETM210
Λ Mount cup spring package(1) and disk 1

(2).
ö Installation position of the cup springs, 2
see below figure.
50DS7ETM120
Μ Install cup springs according to the

1 2 3 4
sketch.
1 = Clutch
2 = Cup springs(9 pcs)
3 = Disk
4 = Retaining ring(50Ý2) 5
5 = Drain valve(piston) 6
6 = Piston with O-Rings
50DS7ETM211

cup springs under a handoperated press
until the retaining ring 50Ý2(1) can be
1
snapped in.
50DS7ETM119
3-117
Ξ Install outer and inner disks alternately
with an inner disk.
2 1
3 = Clutch assy
50DS7ETM212
Ο Mount end plate(1) with the flat side

showing towards the disk package and fix
it by means of snap ring(2)(e.g. 1 2
of the end plate.
50DS7ETM213
Π Equally press on end plate with F

(approx. 18 N to 20 N = 1.8 to 2.0kg) and
set dial indicator to "zero".
E
50DS7ETM214
Ρ Then press end plate against the snap

clearance.
priate snap ring(optional thickness
s=2.0~4.0mm/available in steps
0.25mm).
50DS7ETM215
3-118
΢ Mount axial needle cage 35Ý52Ý2 (1)
2
and axial disk 35Ý52Ý1(1) and oil them.
1
50DS7ETM116
Σ Mount needle cage 35Ý42Ý18(1) and

bush(2) and oil it.
1 2
50DS7ETM115
Τ Mount inner disk carrier until contact is

obtained.
rotations of the inner disk carrier(1). 1
50DS7ETM216
Υ Mount axial washer 35Ý60Ý1(1), axial 3

bearing.
50DS7ETM217
3-119
120ä
C).
50DS7ETM128

2
is obtained. 1

50DS7ETM218

be clearly audible.
50DS7ETM219
3-120
(6) Output
120ä
C).
50DS7ETM128

is obtained.
50DS7ETM220
Ι Heat up bearing inner ring(approx.

120ä
C).
50DS7ETM128
Κ Mount bearing inner ring(1) until contact

is obtained.
50DS7ETM221
3-121
2) R EASSEMBLY OF OIL PRESSURE
PUMP AND REINSTALLATION OF
CLUTCHES
(1) Reassembly of oil pressure pump
ö In case of wear marks in the pump
housing, stator hollow shaft, inner 1
rotor, outer rotor and on the sliding
bearing, the pump assy must be 2
replaced.
3
1 = Stator hollow shaft
2 = Inner rotor 4
3 = Outer rotor
4 = Pump housing with sliding bearing 50DS7ETM48
Η With the sealing lip showing downwards,

carefully insert the shaft seal 55Ý75Ý8
(1) into the pump housing(2) until contact S
is obtained.
1
ö Apply sealing agent(Loctite no. 574) to
the outer diameter.
2
(S) Driver tool 5870 048 219
50DS7ETM222
Θ Mount outer rotor(1) and inner rotor(2).

ö The driver pins of the inner rotor (see 2
arrows) are to be fitted in upward
direction.
1
50DS7ETM223
3-122
Ι Fit stator hollow shaft(1).
50DS7ETM224
Κ Fix stator hollow shaft radially with two

cylindrical screws(1). 1
ö Do not tighten the cylindrical screws -
just turn them in until contact is
obtained and then turn them back by
2
approx. Φ rotation.
Place O-ring(2) 135Ý3 into the annular
groove and grease it.
50DS7ETM225
Λ Insert filter(1).
1
50DS7ETM226
Μ Wet mounting face bell housing with

Loctite(type no. 574).
50DS7ETM227
3-123
Ν Fit two adjusting screws(S) and position
converter bellhousing(1) equally until
contact is obtained. 1
ö Pay attention to the hole pattern. s
(S) Adjusting screws(M10) 5870 204 007
50DS7ETM228
Ξ Force the cylindrical pins 12Ý24(1) into

the holes(blind holes) until contact is 1
obtained.
50DS7ETM229
Ο Fix converter bell housing(1) with

1
cylindrical screws M10Ý30(2).
Tightening torque(M10/8.8Ý30) - - - - - - - - - - - - - - 2
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - MA = 46Nm
50DS7ETM230
Π Fit two adjusting screws(S) and mount

preassembled pump(1). 1
s
ö Pay attention to the hole pattern.
(S) Adjusting screws(M8) 5870 204 011
50DS7ETM231
3-124
Ρ Position transmission pump with 3
cylindrical screws(1) M8Ý60(3Ý120ä 1
offset position) equally until contact is
obtained.
ö Do not damage(shear off) the O-ring.
50DS7ETM232
΢ Fix transmission pump with cylindrical

screws M8Ý60(1). 1
Tightening torque (M8/8.8Ý60) - - - - - - MA = 23Nm
50DS7ETM233
Σ Fix pump with cylindrical screws(1 and

2).
1 = M8Ý16
2 = M8Ý35 1
2
Tightening torque M8/8.8Ý16 ------- MA = 23Nm
ö New cylindrical screws are to be fitted
on a general basis.
ö These cylindrical screws are already 50DS7ETM234
provided with adhesive (microcapsule).

The microcapsule bursts when the
1
screw is turned in, wets screw and nut
thread and hardens.
Mount O-ring 30Ý3(1) onto the suction
tube(2) and grease it.
1
50DS7ETM235
3-125
Τ Fix suction tube(1) with cylindrical screws
M8Ý16(2).
ö When reusing the cylindrical screws,
they must be secured with Loctite no. 1
243.
ö New cylindrical screws are already
50DS7ETM236
thread and hardens.
Υ Insert all bearing outer rings into the

bearing holes of both housing parts(see 1
figure TM236 and TM237).
2
1 = KV clutch - forward 3
2 = KR clutch - reverse and input 4
3 = KD clutch - 2nd gear 5
4 = KC clutch - 1st gear
5 = KE clutch - 3rd gear
6 = Output 6
50DS7ETM237
ö Place bearing outer rings into the bear-
ing holes using assembly grease.

and input are not replaced, it is imper- 7
1
ative to ensure the previous 2
pairing(bearing inner ring/bearing 4
outer ring) - see page 3-78 TM40 and 3
5
TM41.
Insert O-ring 24Ý2.5(7) into the hole and
6
grease it.
50DS7ETM238
(2) Reinstallation of clutches

Η Align and grease rectangular ring 30Ý2
(1). 2
Position clutch KC(2). 1
50DS7ETM239
3-126
Θ Align and grease rectangular ring 30Ý2
(1).
2
Position clutch KD(2).
1
50DS7ETM240
Ι Align and grease rectangular rings 50Ý

2.5(1).
2
Position clutch KR- input(2).
1
50DS7ETM241
Κ Align and grease rectangular ring 30Ý2

(1).
2
Position clutch KV(2).
1
50DS7ETM242
Λ Position output shaft(1) together with

screen sheet(2).
2 1
ö Bolts(3) of screen sheet must be fixed
into the pilot holes.
3 3
50DS7ETM243
3-127
Μ Align and grease rectangular ring 30Ý2
(1).
2
Position clutch KE(2).
50DS7ETM244
Ν Align and grease rectangular rings(1).

1
1
50DS7ETM245
Ξ Use the lifting device to carefully bring the

transmission housing rear part into
contact position.
ö Bolts(1) of screen sheet must be fixed
into the pilot holes.
ö Wet mounting face with Loctite (type
no. 574).
50DS7ETM246
3-128
Ο Hand-tighten the transmission housings
crosswise with 2 cylindrical screws(1).
2
2
Fit cylindrical pins 12Ý24(2) centrically to
the mounting face.
Tighten the transmission housing front
and rear part crosswise with 4 cylindrical
1
screws M10(1).
Tightening torque --------------- MA = 46Nm
50DS7ETM247
Transmission rear part is not fixed to
the holding fixture and could get loose
after turning.
Secure the connection with cylindrical
screws.
Π Fix transmission housing front and rear

3 2 1
part by means of cylindrical screws(1 and
2).
Fit bracket(3).
Cylindrical screws(1) M10Ý30(11EA)
4
Cylindrical screws(1) M10Ý50(17EA)
Tightening torque(M10/8.8Ý30) - - - - - - MA = 46Nm

Tightening torque(M10/8.8Ý50) - - - - - MA = 46Nm
50DS7ETM248
4 = cylindrical pin 12Ý24
3-129
3) REASSEMBLY OF OUTPUT FLANGE
Η Use driver tool to fit the shaft seal 70Ý
100Ý10(1) until contact position, with the
1
sealing lip showing towards the oil sump.
(S) Driver tool 5870 048 057
ö Fill space between sealing lip and dust
lip with grease.
ö Wet outer diameter with spirit.
50DS7ETM249
Θ Heat up output flange(approx. 120ä

C).
50DS7ETM250
Ι Mount output flange(1) until contact is

obtained.
ö Adjust output flange after cooling 1
down.
50DS7ETM251
Κ Insert O-ring 38Ý4 into the space

between output flange and shaft.
1 2
Fix output flange by means of washer(1)
and hexagon screws 10Ý25(2).
50DS7ETM252
3-130
4) R EASSEMBLY OF CONVERTER
SAFETY VALVE AND MAIN PRESSURE
VALVE
(1) Reassembly of converter safety valve
Η Insert valve(1) with drift(S) into the
housing until contact is obtained.
(S) Drift 5870 705 012 1
S
50DS7ETM253
Θ Place compression spring(1) into the

transmission hole and fit screw plug M38
Ý1.5(2) with O-ring 35Ý2(3).
Tightening torque - - - - - - - - - - - - - - - - - - MA = 46Nm 1
2
50DS7ETM33
(2) R eassembly of main pressure valve

(control pressure valve)
Η Main pressure valve consists of :
1 = Screw plug M22Ý1.5 with O-ring 4
19Ý2 2
2 = Piston 1
3 = Spacer ring(2 pcs)
Recommended value 5mm
3
4 = Compression spring
50DS7ETM32
ö The main pressure 16+3 bar is determined
by means of the spacer rings.
Gradation of available spacer rings see
parts manual.
Tightening torque - - - - - - - - - - - - - - - - - - MA = 60Nm
3-131
5) R EASSEMBLY OF CENTRAL SHAFT
(PTO) AND CONVERTER
Η Press tapered bearing(1) onto the central
shaft(2) until contact is obtained. 1
2
50DS7ETM254
Θ Press the toothed disk(1) onto the pump

shaft until contact is obtained.
50DS7ETM255
Ι Mount rectangular ring 50Ý2.5(1).

Grease and centrically align rectangular
ring. 1 3
Mount retaining ring 75Ý2.5(2).
Mount central shaft(3) until contact is
obtained.
50DS7ETM256
Κ Fix central shaft with retaining ring 75Ý

2.5(1).
50DS7ETM257
3-132
Λ Mount converter(1) until contact is
obtained.
1
50DS7ETM24
Μ Position 1 washer/each/thickness=
4
1.0mm (4EA) (1) onto the flexplate 3
mounting webs(4EA).
Place flexplates(2). 2

tion. Spot-welded reinforcing disks of 1
the flexplate to be arranged towards
the outside-see arrows.
Mount washer(3) to the hexagon screw 50DS7ETM258
M10Ý16(4) and fix the flexplates.

Ν Tighten hexagon screws M10Ý16(1).
1
ö When reusing the hexagon screws
they must be secured with Loctite 243.
ö New hexagon screws are already
thread and hardens. 50DS7ETM259
Fix converter axially.

Risk of injury..
3-133
6) REASSEMBLY OF PRESSURE CONTROLLER
(PROPORTIONAL VALVES), INDUCTIVE
SENSOR, SPEED SENSOR(HALL SENSOR),
TEMPERATURE SENSOR, BREATHER AND
SCREW PLUGS
Η Mount breather (1).
1
50DS7ETM260
Θ Mount output Hall sensor-(1) onto the

speed sensor, install O-ring 15.5Ý2.6(2)
and fix it with cylindrical screws M8Ý16
(3).
Tightening torque(M8/8.8x16) - - - - - - - - MA = 23Nm 1
ö When reusing the cylindrical screw, it 2
must be secured with Loctite no. 243. 3

ö New cylindrical screw is already
provided with adhesive(microcapsule).
50DS7ETM261
thread and hardens.
Ι Fit positioned parts.

3 4
1 = Inductive sensor with O-ring 15Ý2
- n turbine
2 = Inductive sensor with O-ring 15Ý2 1
- n central gear chain
2
3 = Inductive sensor with O-ring 15Ý2
- n engine
Tightening torque - - - - - - - - - - - MA = 30 Nm
4 = Temperature sensor with O-ring 11Ý2
50DS7ETM262
Measuring point "63" after the
converter
Tightening torque - - - - - - - - - - - - MA = 25Nm
3-134
Κ Fix pressure controller-proportional
valves-(1) with the cylindrical screws
M6x12(2). 2
Tightening torque(M6/8.8Ý12) - - - - - - MA = 9.5Nm

1
50DS7ETM263
Λ Mount all screw plugs(1 and 2) with O

rings.
1 = Screw plug M10x1 with O-ring
8Ý1.5(24EA)
Tightening torque(M10Ý1) - - - - - - - - MA = 6Nm
1
2 = Screw plug 9/16-18 UNF with O-ring
2
11.9Ý2(7EA)
Tightening torque(9/16-18 UNF) - - MA = 15Nm
50DS7ETM264
3-135
7) REASSEMBLY OF FILTER, CLOSING
COMPONENTS, OIL FILLER TUBE
WITH OIL DIPSTICK AND OIL DRAIN
PLUG
Η Place O-rings 34.2Ý3(1) into the holes 1
and grease them.
50DS7ETM265
Θ Attach filter head(1) with cylindrical

screws M8x30 (2).
2
Tightening torque(M8/8.8Ý30) - - - - - - - MA = 23Nm
50DS7ETM266
ö The fine filter(1) has to be fitted as fol-

lows :
Â Slightly oil the seal
Â Turn in the filter until contact with the
sealing surface is obtained, and then
tighten it by hand with approx. 1/3 to 1
1/2 rotation.
50DS7ETM267
3-136
Ι Install O-ring 30Ý3(1) onto the oil suction
tube(2), grease it and fix it with cylindrical 4
screws M8Ý16(3) to the transmission
housing. 2
Mount oil dipstick(4).

Tightening torque (M8/8.8Ý16) - - - - - - MA = 23 Nm 1
3
50DS7ETM268
Κ Fit oil drain plug 7/8-14 UN 2A(1).

Tightening torque(7/8-14 UN 2A) - - - - MA = 30 Nm
Fix identification plate(2) by means of
grooved pins 3Ý5.
50DS7ETM269
ö Before putting the transmission into

operation, fill it with oil according to
Operator's Manual.
50DS7ETM270
3-137
3. DISASSEMBLY OF DRIVE AXLE
1) REMOVAL AND DISASSEMBLY OF WHEEL HUB
(1) Loosen drain plug with a torque wrench(1)

in axle housing and drain oil.
50D7EDA01
(2) Loosen oil drain plug in planetary housing

and drain oil.
50D7EDA02
(3) Loosen 4 socket head bolts and remove

the planetary carrier.
50D7EDA03
(4) Remove O-ring (4) and snap ring (5) from

the housing of planetary.
50D7EDA04
3-138
(5) Remove 3 pins(6) with a plastic hammer.
50D7EDA05
(6) Remove needle bearing(8), planet gear(7)

and thrust washer(9).
50D7EDA06
(7) Remove sun gear(10) and drive shaft(11).
50D7EDA07
(8) Remove snap ring(12) and then remove

sun gear(10) from the shaft(11).
50D7EDA08
3-139
(9) After removing bolt(13), remove ring
gear(14) and torque plate assembly(14)
from the spindle.
ö Must measure the rolling resistance of
tapered roller bearing.
50D7EDA09
(10)Remove C-ring (14) from the ring gear and

pull the spindle (15) out of the ring gear.
50D7EDA10
(11)Pull out bearing inner race on flange using

2ÝM8 bolts.
50D7EDA11
(12)Remove wheel hub from the axle housing

after loosen 14 bolt and 2 nut.
50D7EDA12
3-140
(13)Disassemble drive shaft and disc & plate
assembly.
50D7EDA13
50D7EDA14
(14)After loosing 4 bolt-self adjust (18),

disassemble spring-self 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).
ö Do not reuse damaged square ring.
50D7EDA15
(15)Remove bearing cup from the wheel hub

by using jig and hammer. Shaft seal may
be damaged.
50D7EDA16
3-141
2) DISASSEMBLY OF THE DIFFEREN-
TIAL CARRIER ASSEMBLY
(1) Loosen 12 bolts(1) and then remove
carrier from the housing by using a lifting
machine.
50D7EDA17
(2) For the reassembly, check rolling

resistance and record it. After loosen 2
bolts(2) and then remove backing plate
(3).
50D7EDA18
(3) Before removing differential assembly from

carrier(4), check the location of cap(5) and
mark it for reassembly.
(4) Remove 4 hexagon bolts(6) and cap(5).
50D7EDA19
(5) Remove differential assembly from the

carrier.
(6) Disassemble bearing(6) from the
differential housing and remove 12 bolts
(7).
50D7EDA20
3-142
(7) After removing 12 mounting bolts(8) from
the housing and then disassemble the ring
gear.
50D7EDA21
(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.
50D7EDA22
(8) Remove thrust washer, side gears, pinion

gears and spider and then place them on
the clean place.
50D7EDA23
(10)Loosen 4 bolts (10) and then remove the

drum from the parking brake.
50D7EDA24
3-143
(11)After removing lock nut(11) and then
remove the yoke(12).
(12)Loosen 4 bolts (13) and then remove
parking brake (14) from the carrier
housing.
(13)Remove the drive bevel pinion shaft (15)
carefully busing a plastic hammer.
ö Be careful not to damage bevel pinion
shaft.
50D7EDA25
(12)Remove shim(16) and spacer(17) from

pinion shaft.
Using a bearing puller, disassemble inner
race of taper roller bearing from the pinion
shaft.
50D7EDA26
(13)Remove outer race of taper roller bearing

and shim from the housing by using a jig
and hammer.
ö Do not reuse damaged shims.
50D7EDA27
(14)Remove outer race of taper roller bearing

on the opposite side.
50D7EDA28
3-144
4. REASSEMBLY OF DRIVE AXLE
Clean every parts with cleaner and then remove remained loctite.
ö Be careful not to spill cleaner on your body.
Avoid drinking cleaner 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.
ÂCheck wear, damage or crack for all the parts and replace if needed.
ÂIf the teeth of gear are damaged, replace it as a set.
ÂReplace damaged tapered roller bearing.
ÂDo not reuse deformed shims or worn thrust washers.
ÂPolish the surface on which seal contacted if needed.
1) ADJUSTMENT OF BEVEL PINION SHAFT

Adjusting shims of bevel pinion shaft.
(1) Adjust shim thickness for the bevel pinion
shaft with following method.
Η Measure "E E" distance on the housing.
Θ By the equation "X = E- B- TÜ C+ 0.25 ",
define the shim thickness(1).
B : Mounting dimension of bevel pinion
shaft , 131.10mm (5.2 in) 50D7EDA29
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 (6.4in)
B is factory dimension
"B" = 131.10mm (5.2in)
Front the bearing
"T" = 31.75mm (1.5in)
Carved seal on the pinion
50D7EDA30
"C"= 0.05mm (0.002in)
Shim thickness :
"X" = 162.85 -131.10 - 31.75 + 0.05
= 0.45mm (0.022in)
ö If teeth are damaged, replace it as a set
(bevel gear and shaft).
Do not reuse damaged shims and
bearings.
3-145
(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.
50D7EDA31
(3) Heat inner race of bearing to max 100Á C

and then assemble it to the pinion shaft.
Also inner race should contact with
bearing place.
Â Measuring play of bevel pinion shaft end

Measure shim thickness by following
method.
Dimension "Q" : Distance from bearing
50D7EDA32
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 :
Z = 2.25 + 3.15 = 5.40mm (0.21in) 50D7EDA33
Unit : mm(in)
P Q Z
2.25(0.089) 3.15(0.124) 5.40(0.213)
2.30(0.091) 3.15(0.124) 5.45(0.215)
2.35(0.093) 3.15(0.124) 5.50(0.217)
2.40(0.094) 3.15(0.124) 5.55(0.219)
2.45(0.096) 3.15(0.124) 5.60(0.220)
50D7EDA34
3-146
2) ADJUSTMENT OF PINION SHAFT
(1) Assemble bearing cup.
Assemble spacer to the pinion shaft and
then install measured shims onto the
spacer.
50D7EDA35
(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.
ÂTightening torque : 45~51kgfÂm
(325~369lbfÂft).
Measure rolling resistance of pinion shaft.
50D7EDA36
ÂRolling resistance : 0.20~0.41kgfÂm

(1.4~2.9lbfÂft).
Coke lock nut into the pinion shaft slot.
3-147
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.
50D7EDA37
(2) Assemble differential housing.

ö Check marks on the housing.
Match two marks at the same position.
50D7EDA38
(3) Tighten 12 bolts(1) to the differential

housing.
bolt.
ÂTightening torque : 5.0~7.5kgfÂm
(36~54lbfÂft)
50D7EDA39
(4) Assemble ring gear by tightening 12

bolts(2).
bolt.
ÂTightening torque : 12.5~14.5kgfÂm
(90~105lbfÂft)
50D7EDA40
3-148
(5) Install differential assembly into the carrier.
Place the bearing cup and screw into the
housing. At this moment, using a screw
adjust rotation backlash.
Install the dial gauge on the gear tooth and
measure the backlash while rotating bevel
gear.
ÂRotation backlash : 0.18~0.23mm
(0.007~0.009in) 50D7EDA41
Unit : kgfÂm (lbfÂft)

(6) Assemble bearing cap. P Z
ö Fix bearing cap with hexagon bolt.
0.20(1.45) 0.30~0.36(2.17~2.60)
ÂTightening torque : 15.0~17.0kgfÂ Âm
0.25(1.81) 0.35~0.41(2.53~2.97)
(108~123lbfÂft)
0.30(2.17) 0.40~0.46(2.89~3.33)
Measure rolling resistance of tapered
roller bearing. 0.35(2.53) 0.45~0.49(3.25~3.54)
The following table shows the relation
between preload(P) of bevel pinion
shaft and rolling resistance(Z).
(calculated at adjustment of pinion shaft
Θ).
(7) Confirm that the screw contacts to the 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
15.0~17.0kgfÂm(108~123lbfÂft).
(10)Assemble plate with hexagon bolts. Apply loctite #271 or #277 to the tapped side of bolt and then
assemble it with tightening torque of 0.80~1.20 kgfÂm(5.8~8.7lbfÂft).
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.
3-149
4) ASSEMBLING 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(79.6~94.0lbfÂft).
50D7EDA42
(3) Assemble brake drum to yoke with tighting

4 bolts (2).
Apply loctite #271 or #277 to thread of bolt
and then assemble it with tightening
(4) Close hole (3) with rubber plug.
50D7EDA43
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 opposite direction of the arrow sign by four click.
At that case, lining clearance is 0.1~0.25 mm.
Κ Check drum drag after operating lever several times.
(Repeat from begining if drag is occured)
50D7EDA44
3-150
6) ASSEMBLING WHEEL HUB ASS'Y
(1) Insert bearing into wheel hub.
ö Apply grease or oil to shaft seal and then
assemble it with proper direction (outer
side of wheel hub).
50D7EDA45
(2) Install wheel hub assembly to the spindle

completely.
50D7EDA46
(3) Insert the spindle into ring gear and

secure with circlip.
50D7EDA47
(4) Place heated tapered roller bearing inner

race into the spindle until contact take
places. Install it on the wheel hub after
cooling down.
50D7EDA48
3-151
(5) Install the torque plate to fix the spindle.
Apply loctite #5127 to axle housing
surface which contact to the spindle.
50D7EDA49
50D7EDA50
(6) Assemble square ring(2), (3) to the axle

housing(1) then apply the oil (Mobilfluid
#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
14~16kgfÂm(101.3~115.7lbfÂft).
Assemble 3 brake pins(8) to axle housing.
ö C heck the status of square ring and
replace if damaged.
50D7EDA51
50D7EDA52
3-152
Assembling plate and inspection
Η Assemble 5 plates(9) and 4 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 spline collar to the axle
housing with the drive shaft. 50D7EDA53
- Before assembling, clean all of the parts

completely and remove burrs.
Ι After assembling, confirm that the
clearance between the outer plate and
the axle housing surface is 2.1~2.6mm
(0.08~0.10in).
50D7EDA54
(7) Push pre-assembled wheel hub to the axle

housing until contact take places.
50D7EDA55
(8) Tighten the torque plate until the wheel

hub assembly has the same rolling
resistance as before.
Apply loctite #271 or #277 to thread of bolt
(13) and then assemble it with tightening
50D7EDA56
3-153
(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.
50D7EDA57
(10)Assemble internal components of

planetary carrier with the reverse order of
disassembly.
50D7EDA58
50D7EDA59
(11)Install planetary carrier assembly to wheel

hub and tighten bolt (2).
(180.9~289.3lbfÂft).
50D7EDA60
3-154
(12)Assemble wheel hub and tighten plug(14).
(253.2~434.0lbfÂft).
50D7EDA61
3-155
GROUP 4 ADJUSTMENT
1. CHECKING THE RING GEAR

BACKFACE RUNOUT
Runout specification : 0.20mm(0.008-inch)
maximum INDICATOR
1) Attach a dial indicator on the mounting Rotate ring gear .

flange of the carrier.
2) Adjust the dial indicator so that the plunger
or pointer is against the back surface of the
ring gear.
3) Set the dial indicator to zero(0).
4) Rotate the ring gear and read the dial
indicator. The runout must not exceed D507AX53
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".
5) Check the differential parts, including the
carrier, for problems that may cause the ring
gear runout to exceed specifications.
Repair or replace parts.
6) Re-install the differential and ring gear into
the carrier. Refer to "Assembling the
differential case".
7) Repeat the preload adjustment of the
differential bearings.
3-156
2. ADJUSTING THE GEARSET BACKLASH
Backlash specification : 0.13~0.18mm
(0.005-0.007inch)
If the old gearset is installed, adjust the
backlash to the setting that was measured
before the carrier was disassembled.
If a new gearset is installed, adjust the
backlash to the correct specification for new
gear sets.
1) Attach a dial indicator on the mounting
flange of the carrier.
2) Adjust the dial indicator so that the plunger
or pointer is against the tooth surface, near
the heel end of the gear tooth. Set the
indicator dial to zero(0).
3) Hold the drive pinion in position.
4) Read the dial indicator, while rotating the
ring gear a small amount in both directions, D507AX54
against the drive pinion teeth.

ö When you adjust backlash, move the ring
gear ONLY. DO NOT move the drive pinion.
Tighten adjusting ring this side
5) 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). Increase backlash
ö Backlash is increased by moving the ring Loosen adjusting ring this side
gear away from the drive pinion. Backlash
is decreased by moving the ring gear D507AX55
toward the drive pinion.

6) Loosen one bearing adjusting ring one
notch, then tighten the opposite ring the Loosen adjusting ring this side
same amount.
Decrease backlash
D507AX56
3-157
3. ADJUSTING TOOTH CONTACT
PATTERN OF THE GEARSET
Always check tooth contact pattern on the
TOP
drive side of the gear teeth. TOE
1) Apply marking compound to approximately

12 teeth of the ring gear.
HEEL
BOTTOM
DRIVE SIDE
(CONVEX)
D507AX57
D507AX58
2) Rotate ring gear forward and backward so

that the 12 marked teeth go past the drive
pinion six times to get a good contact
pattern.
3) Compare the contact patterns.

In new gearsets, a good contact pattern is
toward the toe of the tooth, and centered
between the top and bottom of the tooth. GOOD HAND-ROLLED PATTERN
In used gearsets, a good contact pattern fills D507AX59
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 requires adjustment
along the length of tooth(toe/heel), follow
HIGH PATTERN
step 6)-7). D507AX60
3-158
LOW PATTERN
D507AX61
GOOD PATTERN IN OPERATION (USED GEARS)

D507AX62
4) High pattern : A high contact pattern

Move pattern toward
indicates that the pinion was installed too
bottom
shallow into the carrier.
To correct, move the pinion toward the ring
gear by decreasing the shim pack between
pinion spigot and inner bearing cone. Refer
to "Assembling the pinion bearing cage".
Decrease shim pack
D507AX63
5) Low pattern : A low contact pattern

Move pattern toward
indicates that the pinion was installed too
top
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
Increase shim pack
bearing cage".
D507AX64
3-159
6) Heel pattern : Decrease the gearset Move pattern toward toe
backlash(within specified range) to move Move pattern toward toe
contact pattern toward toe and away from
heel. Loosen adjusting ring this side
Refer to "Adjusting the gearset backlash".
Decrease backlash
D507AX65
7) Toe pattern : Increase the gearset back- Move pattern toward heel
lash(within specified range) to move contact Tighten adjusting ring this side
pattern toward heel and away from toe.
Refer to "Adjusting the gearset backlash".
Increase backlash
Loosen adjusting ring this side
D507AX66
3-160
GROUP 1 STRUCTURE AND FUNCTION
1. OUTLINE
ö The brakes are operated by a pressure compensated, closed center hydraulic system.
Flow is supplied by a fixed displacement, gear type brake pump.
BRAKE SYSTEM
The fixed displacement brake pump supplies flow to the cut-off valve for service brake circuit.
It flows to two accumulator. The accumulator has a gas precharge and an inlet check valve to
maintain a pressurized volume of oil for reserve brake applications.
Oil through the accumulator flows to the brake valves. The brake valve is a closed center design,
dual circuit operated by a pedal.
The brake system contains the following components:
ÂHyd pump
ÂCut-off valve
ÂBrake valve
ÂAccumulators
ÂPressure switches
PARKING SYSTEM
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 cable and lever arm
in drum brake assembly on the drive axle.
4-1
FULL POWER HYDRAULIC BRAKE
SYSTEM
ADVANTAGES - The full power hydraulic Response time
brake system has several advantages over Full power brake actuation VS
Air/Hydraulic brake actuation
traditional brake actuation systems. These
systems are capable of supplying fluid to a 1000
range of very small and large volume
900
service brakes with actuation that is faster
than air brake systems. Figure represents 800
a time comparison between a typical Brake pressure
700 (Full power)
air/hydraulic and full power hydraulic brake
Brake torque(lbÂin)
actuation system. 600
Brake pressure
Full power systems can supply significantly 500 (Air/hydraulic)
higher brake pressures with relatively low 400 Brake torque
reactive pedal forces. The reactive pedal (Air/hydraulic)
force felt by the operator will be proportional 300
Brake torque
to the brake line pressure being generated. 200 (Full power)
This is referred to as brake pressure
100
modulation.
Another key design feature of full power
0 1 2 3 4
systems is the ability to control maximum
Time(Seconds)
brake line pressure. In addition, because
these systems operate with hydraulic oil,
filtration can be utilized to provide long
component life and low maintenance
operation.
Because these systems are closed center,
by using a properly sized accumulator,
emergency power-off braking that is
identical to power-on braking can be
achieved. These systems can be either
dedicated, where the brake system pump
supplies only the demands of the brake
system or non-dedicated, where the pump
supplies the demands of the brake system
as well as some secondary down stream
hydraulic devise.
Another important note is that all seals
within these system must be compatible
with the fluid medium being used.
4-2
2. HYDRAULIC CIRCUIT
8
LIFT TILT AUX AUX
P
1 2 3 4 5 6 7 8
9
F1 F2
10 PP B
7
17MPa
A1
PS T2 Return Steering Return
line MCV unit line
11
12.5MPa ~
15MPa
12 T1
EF CF LS
A2
3MPa ~
4MPa
3
6MPa
P T3
13
14
6 BL
To Axle
T
P BR
1
2 E/G T/M
From Axle
18
17
50D7EBS01
1 Main pump 8 RCV 13 Line filter

2 Brake pump 9 Line filter 14 Pressure switch
3 Priority valve 10 Accumulator 17 Strainer
6 Brake valve 11 Pressure switch 18 Return filter
7 Cut-off valve 12 Accumulator
4-3
1) SERVICE BRAKE RELEASED
8
LIFT TILT AUX AUX
P
1 2 3 4 5 6 7 8
9
F1 F2
10 PP B
7
17MPa
A1
line MCV unit line
11
12.5MPa ~
15MPa
12 T1
EF CF LS
A2
3MPa ~
4MPa
3
6MPa
P T3
13
14
6 BL
To Axle
T
P BR
1
2 E/G T/M
From Axle
18
17
50D7EBS02
When the pedal of brake valve(6) is released, the operating force is eliminated by the force of the
spring, and the spool is returned.
When the spool removes up, the drain port is opened and the hydraulic oil in the piston of axles
return to the tank.
Therefore, the service brake is kept released.
4-4
2) SERVICE BRAKE OPERATED
8
LIFT TILT AUX AUX
P
1 2 3 4 5 6 7 8
9
F1 F2
10 PP B
7
17MPa
A1
line MCV unit line
11
12.5MPa ~
15MPa
12 T1
EF CF LS
A2
3MPa ~
4MPa
3
6MPa
P T3
13
14
6
BL To Axle
T
P BR
1
2 E/G T/M
From Axle
18
17
50D7EBS03
When the pedal of brake valve(6) is depressed, the operating force overcomes the force of the
spring, and is transmitted to the spool. When the spool moves down, the inlet port is opened, and
at the same time the hydraulic oil controlled the pressure level by the cut-off valve(7) enters the
piston in the front and rear axles. Therefore, the service brake is applied.
4-5
3) DO AEB WORK
(1) Start engine after parking the machine on flat floor and blocking wheels.
(2) Release parking brake.
(3) With stepping on the service brake, operate T/M STALL(3 stage).
(To avoid defect of clutch pack, repeat 10 sec of operation and 10 sec of placing neutral)
(4) When the T/M oil temperature reaches 75~80ÁC, lock the parking brake and then shift gear to
neutral position to keep the machine at LOW RPM.
(5) Connect the AEB STARTER to T/M controller.
(6) Push AEB STARTER over 3 seconds.
(7) Confirm the status of AEB from the DISPLAY.
Â Normal operation shows "ST, KR, KV, KC, KD, KE" orderly for 3~5minutes.
Â After the successful completion, it displays " OK".
Â With a new controller, it may display "F6" error code before AEB, but after AEB, it will disappear.
(8) In case of abnormal running, it may display "STOP" with the appropriate error code.
(9) After troubleshooting, start the machine again to repeat above.
ö As the STALL operation has to be done, the SERVICE BRAKE must be locked perfectly to avoid
the fatal accident.
4-6
3. 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.
4
~2
)
20
+1
(35
)
+ 12
(10
1)
(59~6
)
(33+1
Inching sensor
Inching pedal stop bolt

50D7EBS04
1) INITIALIZING THE INCHING SENSOR

(1) Start engine after parking the machine on flat floor and blocking wheels.
(2) Release parking brake and keep neutral gear shift.
(3) Adjust the inching sensor linkage so that the regular voltage is supplied to inching sensor when
operating the pedal.
(Regular voltage ; Before pedal operation(1Ü0.1V),
After pedal operation(3.5Ü0.1V))
(4) Stop the engine and then just KEY ON.(Release parking brake, keep neutral gear)
(5) Connect the AEB STARTER to the T/M controller.
(6) Push AEB STARTER over 3 seconds.
(7) If display shows "ăIP", Step on the pedal fully.
(8) If display shows "āIP", release "OK"
(9) After the successful completion, it displays "OK".
(10)In case of abnormal running, it may display "STOP" with the appropriate error code.
(11)After troubleshooting, start the machine again to repeat above.
ö Above works are to be done with the parking brake released, so machine's wheels must be
blocked for safety.
4-7
4. DISK BRAKE
1 2 6 7
3 4 5 8
2 3
View "A"
50D7EAX05
1 Spindle 4 Service piston 7 Drive shaft

2 Steel plate 5 Service collar 8 Parking brake
3 Disk plate 6 Service piston adjust bolt
OPERATION
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 maintain its lining as
drum type brake do. Also with self-adjust of friction plate clearance, it's easy to prevent the brake
performance drop due to friction material wear.
Major components are 4 disk plates(3), 5 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).
4-8
5. BRAKE VALVE
1) STRUCTURE
13-1 13-2
13-5
13-4
13-3
17
18 16 19
19
15 20
25 26
12
11
6
7 4
24 9
T
23 BL
2
P
BR
5
10 1
8 3
110D7EBS07
1 Body 11 Du bushing 17 Torsion spring

2 Spool 12 Pedal plate 18 Snap ring
3 Plug 13 Pedal assembly 19 Hexagon bolt
4 Holder(piston) 13-1 Pedal 20 Hexagon nut
5 Lower spring 13-2 Rubber 23 Plain washer
6 Main spring 13-3 Lock plate 24 Snap ring
7 Spring retainer 13-4 Hexagon bolt 25 Bolt
8 O-ring 13-5 Plate washer 26 Taper plug
9 Oil seal 15 Bellows
10 Snap ring 16 Lock pin 1
4-9
2) OPERATION
BL BR
T P
Hydraulic circuit
Port Port name Port size
T P Main pressure port PF3/8

BL
T Drain port PF3/8
P BR Brake cylinder port PF3/8
BR
BL Pressure switch port PF1/4
110D7EBS08
4-10
(1) Purpose
The purpose of the brake valve is to sensitively increase and decrease the braking pressure when
the brake pedal is actuated.
(2) Ready position
A connection is established between ports(BR) and ports(T) so that the wheel brakes ports(BR)
are pressureless via the returns ports(T).
(3) Partial braking
When the brake valve is actuated, an amount of hydraulic pressure is output as a ratio of the foot
force applied.
The main spring(6) beneath pedal plate(12) is designed in such a way that the braking pressure
changes depending on the angle. In the lower braking pressure range, the machine can be
slowed sensitively.
When the braking process is commenced, the spool(2) is mechanically actuated via main spring
(6). As spool(2) move downward, they will first close returns(T) via the control edges, thus
establishing a connection between accumulator ports(P) and ports(BR) for the wheel brake
cylinders. The foot force applied now determines the output braking pressure. The control
spool(2) is held in the control position by the force applied(Spring assembly above the spool).
After output of the braking pressure, spool(2) is in a partial braking position, causing ports(P) and
ports(T) to close and holding the pressure in ports(BR).
(4) Full braking position
When pedal is fully actuated, end position of the brakes is reached and a connection established
between accumulator ports(P) and brake cylinder ports(BR). Returns(T) are closed at this point.
When the braking process is ended, a connection is once again established between brake
cylinder ports(BR) and return ports(T), closing accumulator ports(P).
(5) Limiting the braking pressure
Pedal restriction bolt(19) on base plate below pedal is used to limit the braking pressure.
(6) Installation requirements
Return lines(T) must be connected directly to the tank.
The connecting lines must be installed is such a way as to permit proper bleeding.
(7) Maintenance of the brake valve
No special maintenance beyond the legal requirements is necessary.
When using high-pressure cleaners on the machine, please make sure that the water jet is not
aimed directly at the brake valve(To prevent damaging the bellows).
For safety reasons the whole of the brake valve must be replaced if parts other than those
listed above are damaged.
4-11
(8) Repair work
When working on the braking system, always make sure that there is absolutely no
pressure in the system. Even when the engine is switched off there will be some residual
pressure in the system.
ö When doing repair work, make sure your environment is very clean.
Immediately close all open ports on the components and on pipes using plugs.
(9) Replacing the pedal cover
Pedal cover(13-2) is simply pulled of by hand. The new pedal cover is pushed over pedal(13-1)
and tightened manually. Fasten the bellows with the strap retainers.
(10) Replacing the complete actuating mechanism
Carefully clamp the unit vertically in a fixture. The actuating mechanism can be removed by
taking out the four bolts. Make sure that main spring (6) does not fall out. When installing the new
actuating mechanism, make sure that main spring (6) is fitted in the right order.
(11) Replacing the bellows
To change bellows(15) it is advisable to remove pedal(13). For this purpose, loosen retaining ring
(18) and knock out pin 1(16) using a mandrill. When knocking out the bolt, make sure that the
mandrill is applied to the side of the bolt without a knurl. Remove pedal(13) and bellows(15).
Now fit the new bellows and proceed in reverse order as described above. The upper portion of
bellows is fastened to piston(4), its lower portion to pedal plate(12) secure the bellows using
clamps.
4-12
6. CUT-OFF VALVE
1) STRUCTURE
4
6 7
A1 T1
T3
PS A2
P
2
3
4 7
PP B
B PP
A1
PS
5
T1
A2
P T3
Hydraulic circuit
50D7EBS35-1
1 Manifold 5 Check valve

2 Solenoid valve 6 Cut-off valve
3 Coil 7 Relief valve
4 Check valve
2) OPERATION
When the pump works, the oil under the pressure flows into P port.
The oil in P port is stored in the accumulator on A3 port.
As the pressure on P line rises to 150bar, the cut off valve(1) starts cut-offing and the oil in the P
port is unloaded. The pressure on P line goes down 120bar by the minute leakage from valve and
other factors.
At this pressure, the cut-off valve starts cutting.
This process is repeated in the regular period of 30~40 seconds.
4-13
7. BRAKE ACCUMULATOR
1) STRUCTURE
Item 81L1-0004
Diameter 110mm
Mounting height 164mm
Nominal volume 0.7˶
Priming pressure 50kgf/cm2
Operating medium Oil
B Operating pressure Max 150kgf/cm2
Thread M18Ý1.5
Priming gas Nitrogen
A
C A Fluid portion C Diaphragm
B Gas portion D Valve disk
(770-3ATM) 4-22
2) OPERATION
(1) Purpose
Fluids are practically incompressible and are thus incapable of accumulating pressure energy. In
hydropneumatic accumulators, the compressibility of a gas is utilized to accumulate fluid. The
compressible medium used in the accumulators is nitrogen.
In braking systems, the purpose of the accumulators is to store the energy supplied by the
hydraulic pump. They are also used as an energy reserve when the pump is not working, as a
compensator for any losses through leakage, and as oscillation dampers.
(2) Operation
The accumulator consists of a fluid portion (A) and a gas portion (B) with a diaphragm (C) as a
gas-tight dividing element. The fluid portion (A) is connected to the hydraulic circuit, causing the
diaphragm accumulator to be filled and the gas volume to be compressed as the pressure rises.
When the pressure falls, the compressed gas volume will expand, thus displacing the
accumulated pressure fluid into the circuit.
The diaphragm bottom contains a valve disk (D) which, if the diaphragm accumulator is
completely empty, closes the hydraulic outlet, thus preventing damage to the diaphragm.
The accumulators can be fitted in the hydraulic circuit, directly on a component or in blocks on
suitable consoles.
They should be fitted in as cool a location as possible.
Installation can be in any position.
4-14
(4) Maintenance of the accumulator
The accumulator should be checked annually. It should be replaced if the initial gas pressure has
fallen by more than 30%(Please refer to Performance testing and checking of the
accumulator).
(5) Disposal of the accumulator
Before the accumulator is scrapped, its gas filling pressure must be reduced. For this purpose,
drill a hole through gas chamber(B) using a drill approx. 3mm in diameter. The gas chamber is
located on the side opposite the threaded port above the welding seam around the center of the
accumulator.
ö Wear safety goggles when doing this job.
(6) Performance testing and checking of the accumulator
The accumulator is gradually pressurized via the test pump; until the initial gas pressure is
reached, the hydraulic pressure in the accumulator will rise abruptly. This is apparent from gauge
M. If the initial gas pressure is more than 30% below the prescribed value, the accumulator
needs to be replaced. If the measuring process needs to be repeated, wait for intervals of 3
minutes between the individual tests. Any accumulator whose initial gas pressure is insufficient
must be scrapped following the instructions under Disposal of the accumulator.
The amount of initial gas pressure can also be checked from the vehicle. Start the vehicle's
engine. The pump will now supply oil to the accumulators. Until the initial gas pressure is
reached, the hydraulic pressure in the accumulator will rise abruptly. This is apparent from the
gauge in the cab. If the initial gas pressure is more than 30% below the prescribed value, that
initial pressure lies outside the permissible range for at least one of the accumulators fitted in the
vehicle. This accumulator can be traced only by using the method described above, i.e. all
accumulators have to be individually tested. The accumulator whose initial gas pressure is
insufficient must be replaced and scrapped following the instruction under Disposal of the
accumulator.
Accumulator M
Safety valve
A
(770-3ATM) 4-23
4-15
(7) Repair work
pressure in the system. Even when the engine in switched off there will be some residual
For safety reasons the accumulators need to be replaced as a whole if damaged.
4-16
8. PRESSURE SWITCHES
1) STRUCTURE
- Normally closed
H1
- Normally open
H2
7407ABS20
ÂTechnical data
H1 H2 Adjusting range Adjusting pressure Voltage
Item Type Medium G
mm mm kgf/cm2 kgf/cm2 V
Parking NC Oil M12Ý1.5 46 9 50 ~ 150 95 Ü 5 Max 42

Charging NC Oil M12Ý1.5 46 9 50 ~ 150 95 Ü 5 Max 42
Brake stop NO Oil M12Ý1.5 46 9 1~10 5Ü1 Max 42
NC : Normally closed NO : Normally open
4-17
2) OPERATION
(1) Purpose
The pressure switches are used to visually or audibly warn the driver of the pressure within the
system.
(2) Make contact / circuit closer
The pressure switch can be fitted in the braking system or directly on one of its components.
The system pressure acts on an absorption area within the switch, making an electrical contact as
the pressure on that area is increased. The resulting current is used to activate a warning facility,
for instance.
(3) Break contact / circuit breaker
The pressure switch can be fitted in the braking system or directly on one of its components.
The system pressure acts on a absorption area within the switch, breaking an electrical contact
as the pressure on that area is increased. The current is now broken, e.g. to deactivate a warning
facility.
No special measures need to be taken.
(5) Maintenance of the pressure switch
When using high-pressure cleaners on the vehicle, please make sure that the water jet is not
directed at the pressure switch(Corrosion of contacts).
(6) Repair work
pressure in the system. Even when the engine is switched off there will be some residual
ö For safety reasons the pressure switch needs to be replaced as a whole if damaged.
4-18
(7) Adjusting and testing pressure switch
The adjusting screw located between the two contact plugs can be set to the desired value within
a certain range. For adjusting range, please refer to the table Technical data on the previous
page.
After making the adjustment, the adjusting screw should be secured using wax or a similar
material.
()
(+) Screw
(770-3ATM) 4-25
4-19
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). 1
(2) Check that parking brake can hold
machine in position when loaded on 20%
slope. If there is no slope available, travel 2
at low speed and check braking effect of
parking brake.
50D7ETA19
4-20
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.
Brake trailing. ÂPedal has no play. ÂAdjust.
ÂPiston cup faulty. ÂReplace.
ÂBrake valve return port clogged. ÂClean.
ÂWheel bearing out of adjustment. ÂAdjust or replace.
Brake chirps ÂBrake trailing. ÂSee above. Brake trailing.
ÂPiston fails to return. ÂReplace.
ÂDisk surface roughened. ÂRepair by polishing or replace.
Brake squeaks ÂDisk surface roughened. ÂRepair by polishing or replace.
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.
Pedal dragging. ÂTwisted push rod caused by improp- ÂAdjust.
erly fitted brake valve.
ÂBrake valve seal faulty. ÂReplace.
4-21
GROUP 3 TESTS AND ADJUSTMENTS
1) Air bleeding should be performed by two

persons :
One rides on truck for depressing and
Vinyl tube
releasing brake pedal : the other person is Air vent plug
on the ground and removes cap from air
vent plug on wheel cylinder.
2) Block the front wheel securely and apply
parking brake.
3) Start the engine.
4) Attach a vinyl tube to air vent plug and
immerse other end of tube into a vessel
Disk brake
filled with hydraulic oil.
5) Loosen air vent plug by turning it 3/4 with a
wrench. Depress brake pedal to drain oil
mixed with air bubbles from plug hole. Drive axle
6) Depress brake pedal until no air bubbles Vessel
come out of air vent plug hole.
7) After completion of air bleeding, securely
tighten air vent plug. Install cap on plug.
8) Same way for the opposite side. 50D7EBS53
4-22
3. ADJUSTMENT OF PEDAL
1) BRAKE PEDAL
(1) Micro switch for parking brake(if equipped)
Η After assembling parking brake and
23
82
parking cable, put the parking brake lever Parking
released. switch
Θ Loosen the nut for parking brake plate to
play up and down. Parking
cable
Ι Move up the plate so that the stopper can Knob
be contacted with the pin and then
reassemble nut.
ÂMicro switch stroke when parking Pin
Nut 50D7EBS05
brake is applied : 2~3mm(0.08 ~ 0.1in)
2) INCHING PEDAL
(1) The angle stroke of the inching pedal :
4
~2
23~25Á 20
)
(2) The adjusting dimension of the adjusting +1
(35
)
+ 12
stopper bolt should be set with 12mm.
(10
59 - 61 mm
Pedal height
Inching pedal stop bolt

50D7EBS31
4-23
1. BRAKE VALVE
1) STRUCTURE
13-1 13-2
13-5
13-4
13-3
17
18 16 19
19
15 20
25 26
12
11
6
7 4
24 9
T
23 BL
2
P
BR
5
10 1
8 3
110D7EBS07
1 Body 11 Du bushing 17 Torsion spring

2 Spool 12 Pedal plate 18 Snap ring
3 Plug 13 Pedal assembly 19 Hexagon bolt
4 Holder(piston) 13-1 Pedal 20 Hexagon nut
5 Lower spring 13-2 Rubber 23 Plain washer
6 Main spring 13-3 Lock plate 24 Snap ring
7 Spring retainer 13-4 Hexagon bolt 25 Bolt
8 O-ring 13-5 Plate washer 26 Taper plug
9 Oil seal 15 Bellows
10 Snap ring 16 Lock pin 1
4-24
2) REASSEMBLY
9 23 24 11
1
(1) Body assembly
1 Body
2 Spool 3 5 2
3 Plug
4 Holder
5 Spring
6 Main spring
15
7 Spring retainer
7 6 4
9 Oil seal 110D7EBS50
11 DU bushing
15 Rubber cover
23 Plain washer
24 Stop ring
Η Install oil seal(9), plain washer(23), stop

ring(24), DU bushing(11).
- Tool : Jig for dry bearing, snap ring plier.
9,11,23,24
110D7EBS51
Θ Install spool(2) into body(1).
110D7EBS52
4-25
Ι Tighten plug(3)
- Tool : 19mm spanner
- Tightening torque : 14.0~16.5kgfÂm
P ress-in the DU bushing(11) with a
exclusive jig.
Be careful of dust and scrap after 3
washing the parts.

1
110D7EBS53
Κ Spring retainer(7), main spring(6) and

holder(4).
6 4
7
110D7EBS54
Λ Holder(4)ĄBody(1)
110D7EBS55
Μ Rubber cover(15)
15
110D7EBS56
4-26
(2) Pedal plate assembly 13-2 13-1
12 Pedal plate
13-1 Pedal
13-2 Pedal cover
13-3 18
13-3 Lock plate
16 Lock pin(pedal)
19
17 Torsion spring
18 Stop ring
19 Hexagon bolt 12 17
16 110D7EBS57
Η Pedal plate(12) assembly

- Tool : 6mm torque wrench
- Tightening torque : 2.5~3.0kgfÂm
12
110D7EBS58
Θ Pre-assemble pedal assembly(13-1, 13-

3) and torsion spring(17) on the pedal
13-1,13-3
plate(12) with a bar of ͚12 and then 17
push the bar with a plastic hammer.
- Tool : ͚12 bar, plastic hammer.
12
110D7EBS59
Ι Lock pin(pedal)(16), stop ring(18).

- Tool : Snap ring plier for axis. 16
To prevent pedal plate from being

damaged stop ring(18) must be
removed before removing lock pin(16).
18
110D7EBS60
4-27
Κ Rubber cover(13-2)
13-2
110D7EBS61
100D7BS20
Λ Hexagon bolt(19)
- Tool : 13mm spanner
- Tightening torque : 2.0kgfÂm
19
110D7EBS62
Never remove the hexagon bolt.

(Pressure setting valve deviation occurs)
4-28
1. OUTLINE
2 P
4
5
LS CF
EF
1
OUTLET
INLET
1 Hydraulic gear pump

MCV P
2 Priority valve
3 Steering unit
4 Steering cylinder
5 Steering wheel
50D7ESE00
The steering system for this machine is composed of steering wheel assembly, steering unit, steering
cylinder, trail 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
4 L R
13.5MPa
T LS P
MCV
EF CF LS
Brake valve
T/M 1
10
14
50D7ESE01
1 Hydraulic gear pump 6 Steering cylinder

2 Priority valve 10 Suction filter
4 Steering unit 14 Hydraulic tank
5-2
1) NEUTRAL
4 L R
13.5MPa
T LS P
MCV
EF CF LS
Brake valve
T/M 1
10
14
50D7ESE02
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(3) 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
through the EF port.
5-3
2) LEFT TURN
4 L R
13.5MPa
T LS P
MCV
EF CF LS
Brake valve
T/M 1
10
14
50D7ESE03
When the steering wheel is turned to the left, the spool(G) within the steering unit(4) connected with
steering column turns in left hand direction.
At this time, the oil discharged from the pump flows into the spool(G) the steering unit through the
spool(D) of priority valve and flows the gerotor(H).
Oil flow from the gerotor 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
4 L R
13.5MPa
T LS P
MCV
EF CF LS
Brake valve
T/M 1
10
14
50D7ESE04
When the steering wheel is turned to the right, the spool(G) within the steering unit(4) connected with
steering column turns in right hand direction.
At this time, the oil discharged from the pump flows into the spool(G) the steering unit through the
spool(D) of priority valve and flows the gerotor(H).
Oil flow from the gerotor 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
A 25
A
L R
L R
P
T
B B
T LS P 26
Hydraulic circuit
10 13 19 15 21 5 23 22 6 8 24 14 4
9 2
26-4
26-3 12 3
26-1
1
26-2 7
SECTION B-B
16
17
18
20 11
25-6 25-5 25-4 25-3 25-2 25-1

SECTION A - A
D507SE32
1 Dust seal 10 O-ring 19 Plate 25-3 Spring seat

2 Retaining ring 11 O-ring 20 Cap screw 25-4 Spring
3 Cap seal 12 Rolled screw 21 Housing 25-5 Spool
4 Thrust bearing 13 Gerotor set 22 Spool 25-6 Bushing
5 Ball 14 Bearing race 23 Sleeve 26 Check valve
6 Pin 15 Bore screw 24 Plate spring 26-1 Guide
7 Spacer 16 Drive shaft 25 Relief valve 26-2 Shim
8 Center spring 17 End cap 25-1 Plug 26-3 Spring
9 Washer 18 Bushing 25-2 O-ring 26-4 Washer
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. PRIORITY VALVE
1) STRUCTURE
LS CF EF 1 7 4
1-1/16-12UNF
P
HYDRAULIC CIRCUIT
LS
7/16-20UNF
EF CF
1-1/16-12UNF 3/4-16UNF
3 5 2 6
50DS7ESE06
1 Body 4 End plug 7 Orifice

2 Spool 5 Spring
3 Spring plug 6 O-ring
2) 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.
5-8
5. STEERING AXLE
1) STRUCTURE
ö Do not remove the stopper bolt unless necessary.
18
41
42
33 23
42
38
35 41
2
36 45 39
44 20
5
4
18
15 14
19
1 13 21
12 22
44 5
45
39 4
38
6
47
46 17
16 3
12
13
2
24 15
14
1110 7
8
28 9
26 5
25 4
43
31
14
27
29
30
32 50DS7ESE24
1 Steering axle 12 Gasket 23 Grease nipple 35 Cover

2 Knuckle 13 Cover 24 Hub 36 Hexagon bolt
3 Thrust bearing 14 Bolt w/washer 25 Hub bolt 38 Support
4 Needle bearing 15 Grease nipple 26 Taper roller bearing 39 Bushing
5 Oil seal 16 Hexagon bolt 27 Taper roller bearing 41 Steer cylinder boot
6 King pin 17 Hexagon nut 28 Oil seal 42 Clamp
7 Thrust washer 18 Link 29 Special washer 43 Hub nut
8 Shim washer 19 Inner race bushing 30 Lock nut 44 Shim(1.0t)
9 Shim washer 20 Link pin 31 Split pin 45 Shim(0.5t)
10 Set screw 21 Special washer 32 Hub cap 46 Hexagon bolt
11 Hexagon nut 22 Split pin 33 Steering cylinder 47 Hardened washer
5-9
2) TIGHTENING TORQUE AND SPECIFICATION
75
.87
Stroke 150mm
Hub nut
43 61.2 kgf.m(443 lbf.ft)
51.
35.1 ~ 47.5 kgf.m

(253 ~ 343 lbf.ft)
50DS7ESE07
Center pin support

Type Unit
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 75.87/ 51.43
Tread mm(in) 1604(63.1)
5-10
Check item Checking procedure
Steering wheel Â 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 Â Check knuckle visually or use crack detection method. If the knuckle is bent, the
tire wear is uneven, so check tire wear.
Steering axle Â Put camber gauge in contact with hub and measure camber.
If camber is not within 0Ü0.5ä; rear axle is bent.
Â Ask assistant to drive machine at minimum turning radius.
Â Fit bar and a piece of chalk at outside edge of counterweight to mark line of
turning radius.
Â If minimum turning radius is not withinÜ100mm (Ü4in)of specified value, adjust
turning angle stopper bolt.
Min turning radius(Outside)
50D-7E 3270mm(128in)
60D-7E 3315mm(130in)
70D-7E 3270mm(128in)
80D-7E 3600mm(141in)
Hydraulic pressure of power Remove plug from outlet port of flow divider and install oil pressure gauge.
steering Turn steering wheel fully and check oil pressure.
ö Oil pressure : 135 ~ 140 kgf/cm2 (132 ~ 137bar)
2. TROUBLESHOOTING
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.
5-11
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
5-12
1. STEERING UNIT
1) STRUCTURE
1
2
18
11
25 3
14
4
14
5 22
26 15 6
23
21
24
8
16 10 24
7
10
19
13
20
17
9
12
50DS7ESE05
1 Dust seal 10 O-ring 19 Plate

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

bled.
D353SE13
5-20
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)
5-21
(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)
5-22
(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)
5-23
(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)
5-24
(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)
5-25
(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)
5-26
(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)
5-27
(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)
5-28
(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)
5-29
(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)
5-30
2. PRIORITY VALVE
1) STRUCTURE
50DS7ESE08
1 Body 4 End plug 7 Orifice

2 Spool 5 Spring
3 Spring plug 6 O-ring
5-31
2) DISASSEMBLY
ö Cleanliness is the primary means of
assuring satisfactory the priority valve life.
Select clean place.
Before removing the piping, clean the
surrounding area of valve ports.
(1) Fix the body(1) in a vise with copper or

CF EF
lead sheets.
Do not over tighten jaws.
(2) Loosen plug(3) for LS port. LS
D353SE14
(3) Remove spring(5).
D353SE15
(4) Remove spool assy(2).

ö Can't remove the orifice(7) from spool(2),
because the orifices were locked at the
spool.
D353SE16
5-32
(5) Remove plug(4) and separate O-ring(6)
and plug(3, 4) individually.
D353SE17
3) ASSEMBLY
ö Clean all metal parts in clean solvent and
blow dry with air and correct any damage,
burrs and rust.
ö Do not wipe dry with cloth or paper towel.
ö Replace seals such as O-ring with new
ones as a rule and coat with grease.
(1) Fix the body(1) in a vise.
(2) Insert the spool(2).
ö Secure the spool(2) remain in their correct
direction.
ö Secure the spool(2) to move smoothly by
finger.
D353SE18
(3) Insert the spring(5) into the body(1).
D353SE19
5-33
(4) Install the O-ring(6) onto plug(3, 4) and
install the plug(3, 4) into the body(1).
ÂTighten torque : 4.5kgfÂm(32.5lbfÂft)
D353SE20
5-34
3. STEERING CYLINDER
1) STRUCTURE
11
10
12
13
5
6
7
8
9
14 1
3
14
2
9
8
7
6
5
13
12
10
11
ö Specifications
ÂCylinder bore : 80mm
ÂOuter diameter : 94mm
ÂStroke(half) : 150mm
ÂRod diameter : 55mm
D507SE21
1 Tube assy 6 Rod seal 11 Back up ring

2 Rod 7 Back up ring 12 O-ring
3 Piston seal 8 Dust wiper 13 Lock washer
4 Gland 9 Snap ring 14 Pin bushing
5 Bushing 10 O-ring
5-35
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(3) 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.
3
D507SE27
(2) Install the rod seal(6) to the position in the

gland(4) applying a slight coat with grease prior
to install.
6
D507SE28
5-36
(3) Install the dust wiper(8) to the gland(4) 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(1).
6
Special tool D507SE29
(5) Using a hook spanner, install the gland(4) ass-

Hook spanner
embly, and tighten it with torque 60Ü6kgfÂm
(434Ü43lbfÂft).
4 D507SE30
(6) After the gland(4) assembly was installed to the

cylinder tube(1), 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. 4
D507SE31
(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.
5-37
4. STEERING AXLE
1) STRUCTURE
ö Do not remove the stopper bolt unless necessary.
18
41
42
33 23
42
38
35 41
2
36 45 39
44 20
5
4
18
15 14
19
1 13 21
12 22
44 5
45
39 4
38
6
47
46 17
16 3
12
13
2
24 15
14
1110 7
8
28 9
26 5
25 4
43
31
14
27
29
30
32 50DS7ESE24
1 Steering axle 12 Gasket 23 Grease nipple 35 Cover

2 Knuckle 13 Cover 24 Hub 36 Hexagon bolt
3 Thrust bearing 14 Bolt w/washer 25 Hub bolt 38 Support
4 Needle bearing 15 Grease nipple 26 Taper roller bearing 39 Bushing
5 Oil seal 16 Hexagon bolt 27 Taper roller bearing 41 Steer cylinder boot
6 King pin 17 Hexagon nut 28 Oil seal 42 Clamp
7 Thrust washer 18 Link 29 Special washer 43 Hub nut
8 Shim washer 19 Inner race bushing 30 Lock nut 44 Shim(1.0t)
9 Shim washer 20 Link pin 31 Split pin 45 Shim(0.5t)
10 Set screw 21 Special washer 32 Hub cap 46 Hexagon bolt
11 Hexagon nut 22 Split pin 33 Steering cylinder 47 Hardened washer
5-38
2) CHECK AND INSPECTION
D1 C A1, A2 B
D2
D3
50DS7ESE25
unit : mm(in)
Criteria
No. Check item Remarks
Standard size Repair limit
A1 OD of shaft 60(2.4) 59.5(2.3)
A Shaft
A2 ID of bushing 60(2.4) 59.5(2.3)
B OD of king pin 50(2.0) 49.8(2.0) Replace
C OD of steering cylinder pin 22(0.9) 21.9(0.9)
D1 OD of pin 22(0.9) 21.9(0.9)
D Knuckle D2 Vertical play - 0.2(0.008) Adjust shim
D3 ID of bushing 22(0.9) 22.5(0.9) Replace
ÂOD : Outer diameter
ÂID : Inner diameter
5-39
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 balance
weight part of the truck. Hub nut
(1) Loosen the hub nut and take off the steering
wheel tire.
D353SE24
(2) Remove Hub cap.

(3) Pull out split pin and remove lock nut, washer.
Hub cap
(4) Using the puller, take off the hub together with Spilt pin
Lock nut
the roller bearing.
Washer
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.
ö Don't use same oil seal twice.
Knuckle
(7) Repeat the same procedure for the other side. Oil seal
Moreover, when disassembling is completed, Roller bearing
part the lock nut in the knuckle to protect the Hub
Roller bearing
threaded portion.
D507SE26
(8) Loosen set screw(10) and nut(11).

(9) Loosen with washer bolt(14) and remove cover
(13), gasket(12). Remove grease nipple(15).
(10) Push out the king pin(6) without damaging the 15 14 20
knuckle arm(2). 13
12 5
(11) At the same time the king pin is removed, pull 4
out the oil seal(5). 6 21

22
(12) If defect is observed in needle bearing(4), pull it

out by using extractor. 12
13 2
(13) Remove spilt pin(22), special washer(21) and 15
14 1110
link pin(20). 5
4
D507SE37
5-40
4) ASSEMBLY
ö In reassembling, have all parts washed, grease
applied to lubricating parts, and all expendable 15 14
items such as oil seal and spring washers 13
12
replaced by new ones.
4
Perform the disassembly in reverse order. 6
Notch
(1) Tighten the set screw(10) of king pin(6).
3
(2) There is a notch in the middle of the king pin(6), 12
2
make sure that this notch is on the set screw 13
15
side. 14 1110
4
(3) Do not hammer to drive in needle bearing(4)
because it will break.
28
Always use drive-in tool. In assembling the thrust 26
bearing(3), be sure that the fixed ring of the

bearing is placed in position facing the
knuckle(2).
Hub
(4) Hub
31
Η Mount oil seal(28) and inner race of tapered 27
29
roller bearing(26) on the knuckle. The bearing 30
32
should be well greased before assembling.
Θ Install the outer race of the bearing(27) in the
wheel center and assemble to the knuckle. 4~6kgf
Ι Put washer(29) in place, tighten with nut(31)
and locked with split pin(30). In locking with split
pin, locate the hole for the split pin by turning
the nut back 1/6 of a turn. Adjust the preload
D507SE38
of bearing.
Κ Mount the hub cap(32).
Bearing should be well greased before assem-
bling.
5-41
8
19 20
LIFT TILT AUX AUX
T
21
P
1 2 3 4 5 6 7 8
16 15
5 L R
4
1A 1B 2A 2B 3A 3B 4A 4B
9
F1 F2
18.5MPa
13.5 MPa
10 PP B
7 T LS P
17MPa
A1
15MPa
PS T2
11
12.5MPa ~
15MPa
12 T1
EF CF LS
A2
3MPa ~
4MPa
3
6MPa
P T3
13
6 14
BL
To Axle
T
P BR
1
2 E/G T/M
From Axle
18
17
50D7EHS01
1 Hydraulic gear pump 8 Remote control valve 15 Down control valve

2 Axle cooling pump 9 Suction filter 16 Down safety valve
3 Priority valve 10 Accumulator 17 Strainer
4 Main control valve 11 Pressure switch 18 Return filter
5 Steering unit 12 Accumulator 19 Lift cylinder
6 Brake valve 13 Line filter 20 Tilt cylinder
7 Cut-off valve 14 Pressure switch 21 Steering cylinder
6-1
1) WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION
8 19 20
LIFT TILT AUX AUX
P
1 2 3 4 5 6 7 8
16 15
1A 1B 2A 2B 3A 3B 4A 4B 4
Cut off valve

Return line 18.5MPa
15MPa
Steering system
EF CF LS Steering return line
Brake system
T/M
1
Brake return line
18
17
50D7EHS02
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(4) and then goes to the large
chamber of lift cylinder(19) by pushing the load check valve of the spool.
The oil from the small chamber of lift cylinder(19) returns to hydraulic oil tank 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 19 20
LIFT TILT AUX AUX
P
1 2 3 4 5 6 7 8
16 15
1A 1B 2A 2B 3A 3B 4A 4B 4
Cut off valve

Return line 18.5MPa
15MPa
Steering system
Brake system
T/M
1
Brake return line
18
17
50D7EHS03
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.
6-3
3) WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION
8 19 20
LIFT TILT AUX AUX
P
1 2 3 4 5 6 7 8
16 15
1A 1B 2A 2B 3A 3B 4A 4B 4
Cut off valve

Return line 18.5MPa
15MPa
Steering system
Brake system
T/M
1
Brake return line
18
17
50D7EHS04
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(4) and then goes to the large
chamber of tilt cylinder(20) by pushing the load check valve of the spool.
The oil at the small chamber of tilt cylinder(20) returns to hydraulic tank 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 19 20
LIFT TILT AUX AUX
P
1 2 3 4 5 6 7 8
16 15
1A 1B 2A 2B 3A 3B 4A 4B 4
Cut off valve

Return line 18.5MPa
15MPa
Steering system
Brake system
T/M
1
Brake return line
18
17
50D7EHS05
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(4) and then goes to the small
chamber of tilt cylinder(20) by pushing the load check valve of spool.
The oil at the large chamber of tilt cylinder(20) returns to hydraulic tank at the same time.
When this happens, the mast tilt backward.
6-5
2. HYDRAULIC GEAR PUMP
1) STRUCTURE
23 8 1 2 11 3 9 4 5 6 7 10
13 12 ,14 ,15 16 17
19 20 18
50D7EHS06
1 Cover 8 Shaft gear 15 Seal

2 Gear housing 9 Drive gear 16 Seal
3 Carrier 10 Gear set 17 Dowel pin
4 Gear housing 11 Shaft 18 Stud bolt
5 Carrier 12 Thrust plate 19 Washer
6 Gear housing 13 Seal 20 Hex-nut
7 Cover 14 Seal 23 Shaft
6-6
3. MAIN CONTROL VALVE
1) STRUCTURE(5 Spool)
21 29 30
Inlet
27
B B
26
SECTION B - B
Outlet
22 24 23 25
3 Work ports
2 3 4 5 5 8
A A 28
1 6
31
C
32
12
13
14 9
15
DETAIL C
20 10 11 19 18 17 16
SECTION A - A
Port name Size
Inlet port 1-5/16-12UNF

Outlet port 1-5/16-12UNF
Gauge port PF1/4
Work port 1-1/16-12UNF 50D7EHS07
1 Inlet section assy 12 Retainer 23 Tie rod

2 Spool section assy(Lift) 13 Retainer 24 Special nut
3 Spool section assy(Tilt) 14 Spring set 25 Special nut
4 Spool section assy(Aux) 15 Spring 26 Plug
5 Spool section assy(Aux) 16 Screw 27 Plug
6 Outlet section assy 17 Spool end 28 O-ring
7 Spool cap 18 Washer 29 Poppet
8 Cap screw 19 Cap screw 30 Spring
9 Spool cap 20 Main relief valve assy 31 Piston
10 Cap screw 21 Port relief valve assy 32 Spring
11 Cap screw 22 Tie rod
6-7
2) LIFT SECTION OPERATION
(1) Lift position
50D7EHS08
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
50D7EHS09
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
50D7EHS10
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
50D7EHS11
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
ÂMain relief valve : 181 bar
achieved, add or remove shims as required. ÂSecondary main relief valve : 147 bar
Κ Tighten lock nut. (For 3, 4 spool only)
Λ Retest in similar manner as above.
D353HS99
(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. REMOTE CONTROL VALVE
1) STRUCTURE
16
A
16 17
A
18
17
16
19
18
20 5
17 6
19
UT1
7
UT2
18 8
20 9
10
19 UT3
UT4
13 11
20 14 UT 1,2,3,4,5,6
3
UT5
UT6
14
3
2 3
1
100D7RCV00
A Lever 7 Metering spring 14 O-ring

1 Nut 8 Seeger ring 15 Kit 3
2 Plug 9 Seeger ring 16 Clamp
3 Body 10 Docking rod 17 Rubber bellows
4 Kit 1 11 Spring 18 Screw
5 Plunger kit 12 Kit 2 19 Support kit
6 Spring guide 13 Tie rod with nut 20 Flange
6-14
2) OPERATION
P
T
A
1 2
HYDRAULIC CIRCUIT
17
(1) Hydraulic functional principle

Pilot devices with end position locks operate as
direct operated pressure reducing valves.
They basically comprise of control lever(A), two T
7
pressure reducing valves, body(3) and locks. 11
Each pressure reducing valve comprises of a P 10
plunger kit(5), a metering spring(7) and a
spring(11). 3
At rest, control lever(A) is held in its neutral position
by return springs(11). Ports(1, 2) are connected to 100D7RCV01
tank port T.
When control lever(A) is deflected, plunger kit(5) is pressed against return spring(11) and
metering spring(7).
Metering spring(7) initially moves docking rod(10) downwards and closes the connection between
the relevant port and tank port T. At the same time the relevant port is connected to port P. The
control phase starts as soon as docking rod(10) finds its balance between the force from metering
spring(7) and the force, which results from the hydraulic pressure in the relevant port(ports 1, 2).
Due to the interaction between docking rod(10) and metering spring(7) the pressure in the
relevant port is proportional to the stroke of plunger(5) and hence to the position of control
lever(A).
This pressure control which is dependent on the position of the control lever and the
characteristics of the control spring permits the proportional hydraulic control of the main
directional valves and high response valves for hydraulic pumps.
A rubber bellows(17) protects the mechanical components in the housing from contamination.
6-15
5. LIFT CYLINDER
13 15 12 10 11 14 1 2 16 17 9 3 6 4,5 7,8
D507HS12
1 Tube assy 7 Cushion seal 13 Dust wiper

2 Rod 8 Retaining ring 14 O-ring
3 Piston 9 Retaining ring 15 O-ring
4 Piston seal 10 Gland 16 Spacer
5 Back up ring 11 Du bushing 17 O-ring
6 Wear ring 12 Rod seal
6. TILT CYLINDER
24 18 22 7,8 12 11 5,6 3 9,10 4 2 1 13 14 15 16 17 23 24 22
19,20,21 25 25
50D7EHS13
1 Tube assy 10 Back up ring 19 Hexagon bolt

2 Rod 11 Lock washer 20 Hexagon nut
3 Gland 12 O-ring 21 Spring washer
4 DU bushing 13 Piston 22 DU bushing
5 Rod seal 14 O-ring 23 Spring-pin
6 Back up ring 15 Piston seal 24 Grease nipple
7 Dust wiper 16 Wear ring 25 O-ring
8 Snap ring 17 Nylon nut
9 O-ring 18 Rod eye
6-16
Within 100mm(3.9in)
1) CHECK ITEM
(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). 50D7EHS16
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)
50D7EHS17
Standard Under 0.6 (0.02)
2) HYDRAULIC OIL
(1) Using dipstick, measure oil level, and oil if
necessary.
(2) When changing hydraulic oil, clean
suction strainer(screwed into outlet port
pipe) and line filter(screwed into inlet
pipe).
D35ATA26
3) CONTROL VALVE
(1) Raise forks to maximum height and
measure oil pressure.
Check that oil pressure is 188kgf/cm2.
(2675psi)
6-17
2. TROUBLESHOOTING
1) SYSTEM
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.
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.
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.
6-18
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

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:
Â Loosen lock nut.
Â Set adjusting nut to desired pressure setting.
Â If desired pressure setting cannot be achieved, add or remove shims as required.
Â Tighten lock nut.
Â Retest in similar manner as above.
6-19
4) LIFT CYLINDER

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.
6-20
1. MAIN PUMP
1) STRUCTURE
20
19
7 18
17
10
12,14,15
16
6
17
12,14,15
16 5
17
12,14,15
16
11
9
4
17 3
12,14,15 17
16 12,14,15
16
11
8
13
2
17
12,14,15
16
23
21
22
50D7EHS23
1 Cover 8 Gear 15 Seal

2 Gear housing 9 Gear 16 Seal
3 Carrier 10 Gear set 17 Dowel-pin
4 Gear housing 11 Shaft 18 Stud bolt
5 Carrier 12 Thrust plate 19 Washer
6 Gear housing 13 Seal 20 Hex-nut
7 Cover 14 Seal 23 Shaft
6-21
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) Tools required for assembly
Η Socket set(1/2ædrive)
Θ Internal snap ring pliers
Ι Shaft seal sleeve or clear tape
Κ Torque wrench(200lbfÂft capacity)
Λ Plastic hammer
Μ Torque wrench box end adapters
3) DISASSEMBLY
(1) Loosen and remove the nuts and washers from
cover.
50D7EMP21
(2) Remove cover and dowel pin stud bolts from cover.
50D7EMP22
6-22
(3) Remove connection shaft, drive gear and driven
gear set from gear housing.
ö When removing the gear housing, keep it as straight
as possible during removal so that it can not happen
scratch or damage to inner surface by touching gear
teeth.
50D7EMP23
(4) Remove gear housing from carrier.

Remove thrust plate from gear housing.
50D7EMP24
(5) Remove bearing carrier from gear housing.
50D7EMP25
(6) Remove connecting shaft from gear set.

Remove thrust plate from gear housing.
50D7EMP26
6-23
(7) After taking out connecting shaft, remove gear
housing, drive gear and driven gear set from cover.
ö When removing the gear housing, keep it as
straight as possible so that it can not happen
scratch or damage to inner surface by touching gear
teeth.
Inspect scoring or excessive wear of shaft and gear
teeth for both drive gear and driven gear set. 50D7EMP27
(8) Remove lip seal from the cover.

ö When remove the lip seal from the cover, take care
not to give any scratch or damage on the surface of
shaft hole or seal bore.
50D7EMP28
4) ASSEMBLY
(1) Throughly clean seal bore, press the shaft seal in to
the seal bore of the cover.
ö Uniform pressure must be used to prevent
misalignment or damage to the seal.
50D7EMP31
(2) Assemble shaft to the cover.

ö Throughly clean mounting surface of the gear
housing for the seals.
50D7EMP32
6-24
(3) Assemble gear housing and thrust plate to the
cover.
50D7EMP33
(4) Assemble gear set and thrust plate, shaft.

ö Throughly clean mounting surface of square seal
and insert the seal in the gear housing, thrust plate.
50D7EMP34
(5) Assemble gear housing to carrier using dowel pin.
50D7EMP35
(6) Assemble gear housing and gear set.
50D7EMP36
6-25
(7) Assemble carrier to gear housing using dowel pins.
Assemble gear housing to carrier using dowel pins.
ö Throughly clean mounting surface of seals, and
then insert seals and thrust plate.
ö Take care not to happen any damage of the seals.
50D7EMP37
(8) Assemble last drive gear and driven gear set to the
drive gear and driven gear set using connecting
shaft.
Assemble cover to gear housing using dowel pin.
ö Throughly clean mounting surface of seals and then
insert the seals and thrust plate.
ö Take care not to happen any damage of the seals.
50D7EMP38
(9) Assemble stud bolts, washers and fasten nuts.

ÂTightening torque for nut : 15 kgÂm
50D7EMP39
6-26
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)
6-27
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 48Ü
5lbfÂft ; Final torque the 3/4 nut to 74Ü
8lbfÂft. 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)
6-28
3. LIFT CYLINDER
1) STRUCTURE
13
5
10 4
3
12
7
11
8
15 6
14
16
17
9
Â I.DÝO.DÝstroke(standard)
85Ý98Ý1335mm
(3.3Ý3.9Ý52.6in)
Â Rod O.D : 60mm(2.4in)
D507HS19
1 Tube assy 10 Gland

2 Rod 11 Du bushing
3 Piston 12 Rod seal
4 Piston seal 13 Dust wiper
5 Back up ring 14 O-ring
6 Wear ring 15 O-ring
7 Cushion seal 16 Spacer
8 Retaining ring 17 O-ring
9 Retaining ring
6-29
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
6-30
4. TILT CYLINDER
1) STRUCTURE
9
10
12
11
3
7
8
23
2
20
21 24
25
22
1
19
22
24
17
24 18 25
16
13
15
14
4
5
6 Â I.DÝO.DÝstroke :
110Ý124Ý338mm
(4.3Ý4.9Ý13.3in)
Â Rod O.D : 50mm(2.0in)
50D7EHS22
1 Tube assy 10 Back up ring 19 Hexagon bolt

2 Rod 11 Lock washer 20 Hexagon nut
3 Gland 12 O-ring 21 Spring washer
4 DU bushing 13 Piston 22 DU bushing
5 Rod seal 14 O-ring 23 Spring pin
6 Back up ring 15 Piston seal 24 Grease nipple
7 Dust wiper 16 Wear ring 25 O-ring
8 Snap ring 17 Nylon nut
9 O-ring 18 Rod eye
6-31
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)
6-32
GROUP 1 COMPONENT LOCATION
26
23
21 25
19
17 22
A
20
18
24
16 1
15
5
14
2
13
3
12
4
5
11
6
E
F
P
STO
U
MEN
ZER
BUZ
50
mp /h
km
7
h
40
30
0
20
10
10
50D7EEL00
1 Beacon lamp 10 High horn 19 Full automatic switch

2 License lamp 11 Cluster 20 Work lamp switch
3 Work lamp 12 Battery 21 Beacon switch
4 Combination switch 13 Master switch 22 Wiper switch
5 Gear selector 14 Buzzer 23 Washer switch
6 Backup alarm 15 OPSS unit 24 Flasher unit
7 Start relay 16 Start switch 25 Relay 5P
8 Accelerator pedal 17 Hazard switch 26 Relay 4P
9 Micro switch 18 Clutch cut-off switch
7-1
GROUP 2 ELECTRICAL CIRCUIT
AIR-CON
WATER FUEL FUEL BACK AIR CLEARNER
CONTROL PANEL TILT HORN ATTACH BRAKE HEATER SENDOR BUZZER SWITCH
HARNESS BRAKE SW SWITCH FAIL SW SEPERATOR
CUT SOL
COMP. COND.
D.P.S
NC
3
BLOWER SWITCH MODE SWITCH
MOTOR
Pa
Pa
A/C SWITCH
COM
sig
Pa
1
2
- +
CN-131
M
BULB
CD-38
CD-10
NO
CN-25
CD-3
CD-4
CN-65
3
2
1
1
1
2
2
COM
NO
NC
B
Y
L
A/C OUT(HI)
FOOT
CN-7
TNS(+)
B
TNS(-)
VENT
COM
GND
L
GND
DEF
MH
IGN.2
ML
LO
2
1
HI
CD-2
GND
151
120
1
2
G8
3
107
160
129
109
304
339
CS-72
G7
G7
G7
125
2
1
124
G7
1 2 3 4 5
211
127
128
G8
G6
CN-20
165
G8
- 1
ILLUMI RELAY 2
GND 3
FUSE BOX 4
CR-23
106 3W
1 2 1
116 1.25BR
THERMOCON 2
105 3BY START RY
M 3
M G7 1.25B
RESISTOR 4 4 3
M/ACT-MODE
COMP. RELAY COND. FAN RELAY
B/L
MOTOR
CN-74
114
2 R
115 U
1
CN-15
L ~ ALTERNATOR
103 3 G
2 B+
101
1
101 CN-95
CN-3
1
KEY SW & 103 100 FUSIBLE LINK
1 2
FUSE BOX
CN-1
151 113
FUSE IG 1
- 2
107 CR-24
FUSE B+ 3
304
CUT SOL RY. 4
124
BACKUP RY. 5
116
NUETRAL RY. 6 GLOW RY
211
FUEL HEATER RY. 7
G1
GND 8
113 CN-80
GLOW RY. AUX 9
120
CLUSTER 10 GLOW PLUG
160
HORN SW. 11
165
TILT ALARM 12
G3
GND 13 CN-45
G1 105
GND 14 M
GND 15
G4 M
100 START MOTOR
106
CN-2 B+
125
CLUSTER 1
110 220
CLUSTER 2
111
CLUSTER 3
128
CLUSTER 4
127
CLUSTER 5
115 35 35B 35B
CLUSTER 6
339
CLUSTER 7
114
FUSE 8
109 BATTERY
FUSE 9 MASTER SW
129 12V X 2
BRAKE LAMP 10
- 11
- 12
CN-11 MAGNETIC
FUSE B+
423
1 CR-44
221
- 2 1
900 G7 000
FUSE IG 3 2
421
PARKING RY. 4
466
INCHING SW. 5
429
AUTO SW 1st 6
444 402 B PUMP MOTOR
AUTO SW 2nd 7
420 902 B
GEAR SEL. AD3 8 +
463
GEAR SEL. AD1 9 M
911
GEAR SEL. F 10 -
443
GEAR SEL. R 11
464 EARTH
GEAR SEL. N 12 CN-147
438 G5
SENSOR EU1 13 2
437 220
SENSOR AU1 14 1
424
SENSOR VMGA1 15
461
SENSOR EU2 16
TILTING MOTOR
CN-10
414
TM DISPLAY 1
425
CAN_H 2
426
CAN_L 3
221
107
106
428
G7
SHIELD 4
5
CS-77
6
9
4
5
8
2
6
3
7
1
10
7 9
2 8 1 7
8 I 0
4 3 10
CAB TILTING SW
HMC ENGINE WIRING

CN-13
755 55 B 55
1 1 E/E
111
2
2P 2
2 G/U
WATER TEMP &
855 155 Y 155
3 ECU
GAUGE SENSOR
3
110 1Y
4
820 120 Y
5
831 131 B 120
6 1 SIG
755 833
7
133 W 131
2 E/E
CAM SPEED
855 133
3 VCC
SENSOR
8
820
831
833
1 E/OIL PS
Pa
CN-14
806 806 106 B
1
843 843 143 B
2
842 842 142 B
3
807 807 107 B 40
4 1
803 803 103 R 41 NE SENSOR
5 2
838 838 138 R
6
837 837 137 R
7
804 804 104 R 134
8 1 GND
893 121,132 COMMON RAIL
9 2 SIG
894 894 S-1 126 PRESS SENSOR
10 3 VCC
892 892 S-2
11
891
12
54
13 1 GND
32
14 2 NTC BOOST
57
15 3 +5V PRESSURE
845 845 144,145 Br 128
16 4 Vout
844 844
17
18
107
19 1
739 739 S-5 104 INJECTOR #4
20 2
847 847 146,147 W
21
846 846
22
428 shield
754 754 54 B 142

23 1
834 834 134 B 137 INJECTOR #3
426
427
449
902
402
403
404
409
410
412
413
414
415
418
419
420
421
423
424
425
429
432
437
438
441
442
443
444
900
446
455
456
461
462
463
464
466
911
468
24 2
740 740 40 R
25
CN-50
26
143
1
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
27
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
1
2
3
4
5
6
7
8
9
757 757 57 W 138 INJECTOR #2

28 2
826 826 126 W
29
VMG1
VMG2
VMGA1
VGS
VMGA2
ADM4
ADM3
ADM2
ADM6
SDDK
EUPR
ADM8
ADM7
ADM1
ADM5
VM1
VM2
741 741
CANB_H
SD1
ER3
ED3
ED7
SD3
SD4
AU1
EU1
ER1
ED4
ED8
ER2
SD2
EU2
ED1
ED5
ED2
ED9
ED6
CANF_H
41 B
VPS2
VPS1
VPS1
VPE1
GANB_L
VPS2
VPS1
VPE2
EF5
EF1
EF6
EF2
EF3
EF4
ED10
CANF_T
ED11
ED12
ED13
CANF_L
-
VPI
AIP5
AIP2
AIP3
AIP7
AIP6
AIP8
AIP4
30
106 AIP1
863 863 163 W
31 1
103 INJECTOR #1
32 2
828 828 128 Y
900
415
902
418
33
832 832 121,132 Y
34
821 821 163
CN-51
2 FUEL TEMP
449
446
419
403
441
403
442
403
900
462
404
35
456
55
412
412
412
412
412
755 755
410
432
455
409
55 B
2
3
4
5
6
1
C SENSOR
TCU(EST-65)
36 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
37 1 23
CD-73
CD-74
CD-72
732 732
CD-27
32 L
CD-80
CD-81
CD-82
CD-83
CD-84
CD-90
2
3
4
5
6
1
38
1
2
2
144,145
1
2
2
3
1
1
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
39 2
SDDK
EUPR
40
146,147
1
SCV
(+)
(-)
C
41 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68
42 KV KR KD KE KC
HMC ENGINE WIRING V/V V/V V/V V/V V/V
DIAGNOSTIC TEMP SPEED SPEED SPEED SPEED
SENSOR PICK-UP PICK-UP PICK-UP SENSOR
ENGINE TURBIN INTERNAL OUTPUT
(TCU)
50D7EEL01
7-2
COMBI
GEAR SELECTOR SW
SWITCH
1
LAMP SW
HO
NEU
1
2
2 3
C
SENSOR
6
1
2
T/M DISPLAY
INCHING
P/METER
BATT(+)
INCHING
2
CAN LOW
CLUSTER
T/M FAIL
P.D
PS
TILT
CAN HIGH
NC
TURN LH
SW
GND(CAN)
PARKING
TURN RH
REV
AMP
WIF(CAN)
RX232C TX
CHARGING
M
RS232C RX
GND(BATT)
OPS LAMP
P
Y
DOWNLOAD
R
3
Gr
HIGH BEAM
1
ALARM
FUEL GAUGE
GND(RS232C)
WORK LAMP
L
FUEL EMPTY
B
ILLUMINATION
GND(SIGNAL)
GND(SIGNAL)
AIR CLEANER
OPSS BUZZER
KEY ON POWER
ANTI RESTART
-
CRUISE SET/DEC
CRUISE ENABLE
FUEL WARMER
B
A
E
B
A
PREHEAT(CAN)
C
D
C
Pa
BRAKE OIL LOW
IVS
E/G OIL PS(CAN)
SIG
ACCEL PEDAL
RESISTER
VCC
24Vdc
Hi 4
2
3
Lo 5
FWD
L
SPEED GAUGE(CAN)
R
BRAKE PRESS LOW
G(ECU)
CN-26
CRUISE RESUME/INC
3 1 2 3
ILL
ENG.WARNING(CAN)
HD
E/G TEMP GAUGE(CAN)

T/M TEMP GAUGE(CAN)
AU1
EU1
AU1
COM
EU2
CHECK
Y
P
B
R
G
B
R
RS232C
X2
X1
ILL
-
B
FRONT WIPER MOTOR
OUTPUT
AD5
AD4
AD6
AD1
AD3
ED1
+
SD1
3
1
4
3
VMGA1
VMGA1
1
2
3
4
5
6
(F)
(R)
(N)
VP
AD5
AD3
AD6
AD4
AD2
AD1
ED1
8
7
6
2
1
4
1
5
3
CN-21
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
1
2
5
3
3
6
2
4
1
20
19
18
17
16
15
14
13
12
11
10
20
19
18
17
16
15
14
13
12
11
10
2
1
4
4
3
6 5 4 3 2
1
2
3
1
2
A
B
C
CN-8
F
CN-56
CS-12
CN-98
CN-169
CN-144
CN-57
B1
B2
R
CS-11
B3
A
A
C
B
C
B
D
D
CD-71
CN-19
165
130
CS-15
AD7 CS-14
G7
G7
G4
G4
G4
G4
G4
G7
G7
900
192
193
190
191
162
161
160
123
122
163
414
426
521
466
111
108
425
523
522
112
115
127
151
128
135
339
110
125
745
164
782
120
305
306
133
122
123
G5
521
522
523
426
425
424
461
437
424
438
437
438
424
721
HORN SW
758
801
825
835
463
420
900
464
443
911
CS-5
G7
160
CS-59
444 444
1
461
437
424
438
429 429
2
I 0
900
3
4
5 1
900 3
6
7 6
2
8 8
AUTO/MANUAL SWITCH
112
9
G7 10 9
10
CS-42
466
1
466
2
3
4
900 1
5 5
900 7
6
2
7 6
8
INCHING SWITCH
8
112
9
G7 10 9
10
CS-69
202
1
202
CL-15 2
129 COMBI WORK WORK COMBI
TA 1 3
112
TU 2 4
123 E C T E C T 117 1
NC 3 5 5
117 7
124
EH 4 6
B
B
B
B
L
W
W
W
FRONT LH
2
FRONT RH
BU 5 7 6
R/COMBI LH
G3 8
CL-4
CL-3
ST 6 8
CL-25
CL-24
REARWORK SWITCH
112
9
G7 10 9
G3
G3
G3
G3
112
122
133
133
112
123
CL-16 10
TA 1 129
TU 2 112
CS-23
122 292
NC 3 1
124 2
EH 4
BU 5 3
R/COMBI RH
G3
ST 6 4
156 1
5 5
156 7
CL-23 6
W 202 2
7 6
BEACON SWITCH
B G3 G3 G3 8
8
REAR
112
9
WORK LAMP
202 202 G7 10 9
CL-7 10
W 292 292 292
12 11 10 9
B G3 129 129
LAMP
CS-41
123 123 123
BEACON
1
122 122 122
6
CL-1 2
151 124 124
5
1 3
LH
G3 133 133
4
2 4
112 112 163 1
5
3
CL-51 5
151 151 163 7
151
2
1 6
108 108 2
RH
G3
ROOM LAMP
2 7 6
8
HAZARD SWITCH
CN-17 8
112
9
151 G7 10 9
ACC 1 10
G3
ILL- 2
G3
GND 3 CS-77
712 192
SPK FRT RH- 4 1
710
SPK FRT LH- 5 2
I 0
190
TEL MUTE 6 3
Hi
ANT 12V 7 4
108 193 1
BACK UP+ 8 5 3
112
ILL+ 9 6
191 5
NC 10 7
Pa
713 7
SPK FRT RH+ 11 8
G3
FRONT WIPER S/W
112
CASSETTE RADIO
Lo
112
REMOCON+ 12 9
G7 10 9
REMOCON GND 13 10
711
SPK FRT LH+ 14
CL-21
NC 15 CS-30
711
710
713
712
I
G3 190
GND 16 1
B
2
WG
0
CN-24
CN-23
3
LICENCE LAMP
4 1
SPEAKER
194 5
5
ANTENA
LH
RH
6
2
7 6
8
WASHER PUMP S/W
112
721
9
758
801
825
835
G7 10 9
10
CN-22
194
2 M
G7
PUMP
1
WASHER
768
6
719
7
G5
9
DIAGNOSTIC
702
16
CN-156
CR-43
774 2 1
ECU 1
702
- 1 2
34
7
RELAY
702
- 2 3
705
- 3 4 4 3
ECU POWER
705
ECU RELAY 5
705A
ECU RELAY 6 CR-47
705B G6
ECU RELAY 7 1 2 1
719 119
CN-151
DIAGNOSTIC 19 16 2
RELAY
721 119
ACCEL SIG 21 15 3
722 719 719 211
ACCEL SIG 22 14 4 4 3
772A
FUEL HEATER
28 758 13
758
ECU CASE G
1
732 825 825
28
INT AIR TEMP 32 12 CR-5
735 721 721 135
+BF 35 11 1 2 1
739 836 835 141
NE SHIELD 39 10 2
69
41
740 782 782 911
40 9 3
RELAY
NE +
741 745 745 116
NEUTRAL
NE - 41 8 4 4 3
43 770 7
770
O/HEAT LAMP
745 774 774
GLOW LAMP 45 6 CR-35
746 911 911 G6
KEY SW 46 5 1 2 1
116 116 116 118
START SIG 48 4 2
7-3
768 768 464
RELAY
IDLE DOWN 51 3 3
CN-152
754 735 735 124
BACK UP
SENSOR G 54 2 4 4 3
755 705 705
SENSOR G 55 1
746A
KEY SW 56 CR-45
757 CN-6 G6
SENSOR PWR 57 1 2 1
758 119
AUX
58 2
35
ACCEL IDLE
62
911 770
NEUTRAL SW 66 3
768 113
DIAGNO SW 68 4 4 3
770
GLOW RELAY
GLOW RELAY 70
76
101
770A
GLOW RELAY 71 CR-13
772 162
EARTH(SIGNAL) 72 1 2 1
773 155
EARTH(SIGNAL) 73 2
774 155
RELAY
ECU RY.COIL 74 3
774A 133
ECU RY.COIL 75 4 4 3
HEAD LAMP
735A
CN-153
+BF 76
782
E/ CHK LAMP 82 CR-40
112
IDLE UP 88 1
156 3 4 6
2
RELAY
156
97
70
4
802 161
POWER G 102 6
803 133 1 2
INJ.#1 TWV1 103 3
ILLUMINATION
804
INJ.#4 TWV3 104
136
806
INJECTOR #1 106 CR-34
807 900
107 L
INJECTOR #4 107 1
820 900 3 4 6
CAM SPEED 120 2
821
CRPS(SIG) 121 4
RELAY
302
ACCEL ACC 123 6
PARKING
825 421 W 1 2
ACCEL ACC 125 3
826
CRPS(VCC) 126
CN-154
828
BOOST SIG 128 CR-11
831 G6
CAM SPEED G 131 3 E
832 154 G
UNIT
CRPS(SIG) 132 2 B
833 163
C/SPEED VCC 133 1 L
FLASHER
129
102
834
CRPS(GND) 134
835
ACCEL GND 135 CR-34
836 132
ACCEL GND 136 1
837 132 3 4 6
INJ.#3 TWV2 137 2
838
RELAY
138 4
143
INJ.#2 TWV4
167
840 307
CUT OFF
TILT/LIFT
POWER G 140 6
841 304 1 2
POWER G 141 3
842
INJECTOR #3 142
843
INJECTOR #2 143
844
SCV LO 144 CN-55
845 132 W
CN-155 SCV LO 145 1 IGN
846 301 Y
SCV HI 146 2 SEAT S/W
847 464 Or
SCV HI 147 3 REV S/W
855 443 L
WTS 155 4 FWD S/W
857 302 G
CAN1_H 157 5 TRAVEL CUT
137
858 307 P
162
CAN1_L 158 6 RELAY 2

863 G6 B
FUEL TEMP 163 7 GND
306 Gr
8 OPS-LAMP
305 V
9
OPS UNIT
858
BUZZER -
-
2 10 BRAKE S/W
857 P
CAN
1 11 RELAY 3
170 R
CN-157 12 BATT +
164 Br
13 PARK'G S/W
14
CN-113
305 1
OPS
170
2
BUZZER
CS-73
1
301
SEAT
2
SWITCH
CS-17 COM
G5 B
1 COM
W
2 NO
164 Br
SWITCH
3 NC NC NO
PARKING
DO-1
164
1
302
2
DIODE
CN-9
425
1
426
TOOL
2
3
428
4
TCU SERVICE
ST
HT
ON
OFF
CS-2
103
1
2
104
2
105
START KEY S/W
1
B BR ACCR1 R2 C
103
103
CN-36 FUSE BOX A

107 HORN/CAB TILT 10A
1
109 STOP LAMP 10A

2
108 CLUSTER/RADIO 10A

3
423 TCU B+ 10A

4
105
702 ECU B+ 20A

5
170 OPSS B+ 5A
6
-
7
132 OPSS IG 10A

8
151 CLUSTER/RADIO 10A

9
119 FUEL HEATER 20A

10
735 ECU IG 10A

11
900 TCU IG 10A

12
104
105
CN-37 FUSE BOX B

114 ALTERNATOR 10A
1
155 HEAD LAMP 15A

2
117 REAR WORK LAMP 10A

3
156 TAIL/BEACON LAMP 10A

4
705
154 TURN LAMP 10A

5
118 BACK UP LAMP 10A

6
130 TILT ALARM 5A

7
190 WIPER MOTOR 10A

8
121 AIR CON 25A

9
-
10
801 ACCEL PEDAL 5A

11
141 START RELAY 10A

12
129
109
114
339
115
127
128
111
110
125
G4
G2
G3
G1
151
165
160
120
113
211
116
124
304
107
103
428
426
425
414
463
420
444
429
466
421
900
423
443
911
461
424
437
438
464
CN-20
8
7
6
8
7
6
1
5
9
5
9
4
1
4
1
8
5
4
1
2
2
6
2
3
3
7
3
9
8
7
6
5
4
3
2
1
1
13
12
11
10
16
15
14
12
11
10
15
14
13
12
11
10
CN-1
CN-3
CN-2
112
CN-11
CN-10
-
2
-
-
G1
840,841,802
WTS
GND
3
732
755
821
832
828
863
741
826
757
740
834
754
846
847
739
844
845
891
892
894
893
804
837
838
803
807
842
843
806
833
831
820
855
755
772
GND
GND
GND
ALT "L"
ALT "I"
AIR-CON
121
HORN
WIF IG
ED4(F)
ED6(N)
ED5(R)
VPI(IG)
4
VPE(B+)
HORN B+
ED1(AD1)
ED3(AD3)
CAN_LOW
CAN_HIGH
BRAKE SW
BRAKE SW
FUEL EMPTY
ATTACH SOL
CAN SHIELD
TITL SWITCH
ED8(AUTO 2)
FUEL SENDER
WIF SENSOR
AIRCLEAR SW
FUEL HEATER
GLOW RELAY
START RELAY
ED11(AUTO 1)
ED9(INCHING)
SD1(DISPLAY)
AU1(SENSOR)
EU1(SENSOR)
EU2(SENSOR)
BRAKE FAIL SW
BATTERY B+
ENG OIL PRESS.
ED10(PARKING)
BACKUP BUZZER
VMGA1(SENSOR)
50D7EEL02
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+)]
Glow relay[CR-24] Glow plug[CN-80]
Start relay[CR-23]
Fusible link[CN-95] Alternator[CN-74(B+)] [CN-3]
Fuse box[CN-36(1)]
I/conn[CN-1(3)] Cab tilting switch[CS-77]
Horn[CN-25]
Fuse box[CN-36(2)] I/conn[CN-2(9)] Brake switch[CD-4]
Fuse box[CN-36(3)] Cluster[CN-56(11)]
I/conn[CN-17(1)] Cassette radio
Fuse box[CN-36(4)] I/conn[CN-11(1)] TCU[CN-50]
Fuse box[CN-36(5)] Diagonostic[CN-156(11)]
Fuse box[CN-36(6)] OPSS unit[CN-55(12)]
OPSS buzzer[CN-113(2)]
2) CHECK POINT
Engine Key switch Check point Voltage
Η - GND (Battery(+))
Θ - GND (Fusible link)
OFF OFF Ι - GND (Fuse No.1) 24V
Κ - GND (Fuse No.4)
Λ - GND (Start key)
öGND : Ground
7-5
CS-77 CN-1
1 WIF IG 1
221
I 0
2
3 - 2
107 107 107
4
2
HORN B+ 3
4
ST
5
8
ON
HT
OFF
ATTACH SOL 4 CS-2
6 103
1
NC
NC
CN-50
3
7 BACKUP BUZZER 5 1
ILL-
GND
ILL+
ACC
7
GND
8
160 Pa
VM1 1 START RELAY 6 2
ANT 12V
9
2
1
2
BACK UP+
VM2
TEL MUTE
9
TCU(EST-65)
10
FUEL HEATER 7
REMOCON GND
REMOCON+
10 CD-4
SPK FRT LH-
CN-25
SPK FRT LH+
SPK FRT RH-
VMG1 3
CAB TILTING SW
SPK FRT RH+
ANTENA
HORN
5
VMG2 4 GND 8
BRAKE SW
2
8
9
7
6
5
4
3
2
1
16
15
14
13
12
11
10
160
107
ADM4 5 GLOW RELAY 9
1
ADM3 6 WIF SENSOR
Cassette radio
108
10
START KEY S/W
B BR ACC R1 R2 C
ADM2 7 HORN 11
POWER CIRCUIT
VPS2 8
TILT SWITCH 12
AIP5 9
AIP2 10 GND 13
ADM6 11 GND 14
1
BATT(+)
VPS1 12 GND 15
CLUSTER
VPS1 13
46
SD1 14
24
1
11
9
2
SDDK 15
47
CN-2
CN-56
CN-17
3
EF5 16
25
103
103
48
ER3 17
3
EUPR 18 CN-36 FUSE BOX A
26
107 HORN/CAB TILT 10A
4
19
49
EF1
1
ED3 20
27
STOP LAMP 10A
2
50
ED10 21
5
CLUSTER/RADIO 10A
3
ED7 22
28
10A
CN-11 423
423 423 423 TCU B+
4
VPE1 23
51
VPE(B+) 1
ECU B+ 20A
5
VMGA1 24
29
2
CANF_H 25 OPSS B+ 5A
52
6
VPI(IG) 3
CANF_L 1 -
30
26
7
CANF_T 27 ED10(PARKING) 4
53
OPSS IG 10A
8
VGS 28 ED9(INCHING) 5
31
6 CLUSTER/RADIO 10A
9
ED11 29
54
ED11(AUTO 1) 6 CN-55
7 W FUEL HEATER 20A
1
10
ED12 30
32
IGN
ED8(AUTO 2) 7 Y
2 ECU IG 10A
ED13 31 SEAT S/W
10
55
11
Or
ED3(AD3) 8 9 3 REV S/W 10A
33
AIP3 32 L
TCU IG
12
DIAGNOSTIC
4 FWD S/W
ADM8 33 ED1(AD1) 9
11
G
56
5 TRAVEL CUT
7-6
ADM7 34 P
34
ED6(N) 10 16
105
6 RELAY 2
SD3 35 B
12
57
ED4(F) 11 7 GND CN-37
OPS UNIT
103
SD4 36 CN-156 Gr
FUSE BOX B
35
8 OPS-LAMP
ED5(R) 12 V ALTERNATOR 10A
1
58
37
13
AU1 9 BUZZER -
-
EU1 38 EU1(SENSOR) 13 10 HEAD LAMP 15A
36
BRAKE S/W
2
P
ER1 11 RELAY 3
14
39 10A
59
CN-3
AU1(SENSOR) 14 R
REAR WORK LAMP
3
EF6 40 12 BATT +
37
VMGA1(SENSOR) 15 Br TAIL/BEACON LAMP 10A
4
13 PARK'G S/W
EF2
103
41
15
60
EU2(SENSOR) 16 14 TURN LAMP 10A
5
EF3 42
38
BACK UP LAMP 10A
6
ED4 43
16
61
ED8 44 TILT ALARM 5A
39
CN-113
7
VPI 45 10A
17
62
1 WIPER MOTOR
8
OPS
VMGA2 46
40
2 AIR CON 25A
9
CANB_H 47
18
63
-
BUZZER
10
GANB_L 48
41
ACCEL PEDAL 5A
11
ER2 49
19
64
AIP7 50 START RELAY 10A
42
12
220
220
106
AIP6 51
20
65
1
ADM1 52
2
1
43
2
VPS2 53
66
21
100
221 CR-44
CN-147
AIP8 54
44
000
35R
55
1
2
AIP4
22
67
AIP1 56
45
105
ADM5 57
68
23
VPS1 58
100
101
101
CN-15 103
- 59
105
106
12V X 2
SD2 60
BATTERY
M
1
2
EU2 61
CN-74
2
1
4
3
EF4 62
-
+
35B
M
R
B+
2
1
ED1 63
CR-23
B+
CN-45
3W
ED5 64
3BY
CN-95
1.25B
CR-24
1.25BR
CN-80
3
ED2 65
TILTING MOTOR
ED9 66
M
GLOW RY
G
4
2
FUSIBLE LINK
U
ED6 67 468
~
GLOW PLUG
2
1
VPE2 68
START MOTOR
ALTERNATOR
MASTER SW
35B
50D7EEL03
START RY
2. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal
Start motor[CN-45(B+)] Fusible link[CN-95] Alternator[CN-74(B+)]
Start relay[CR-23] I/conn[CN-1(6)] Neutral relay[CR-5]
Fuse box B[CN-37(12)] Start switch[CS-2(2)]
TCU[CN-50]
ö The engine can be started only when the gearshift is in neutral position.
The operator should be seated when starting.
(1) When start key switch is in ON position
Start switch ON [CS-2(1)] Fuse box A[No.2 Ą12] Gear selector switch[CS-15(A)]
(2) When start key switch is START position
Start switch START[CS-2(2)] Fuse box B[No. 12] Neutral relay[CR-5(2) Ą (4)]
I/conn[CN-1(6)] Start relay[CR-23]
2) CHECK POINT
Η - GND (Battery B+)

Ι - GND (Fuse box B No.1, 12)
Running ON 24V
Κ - GND (Start key)
Λ - GND (Neutral relay)
öGND : Ground
7-7
CN-1
1
WIF IG 1
ST
ON
HT
NEU
OFF
CS-2
2 3
- 2 103
1
CN-50 HORN B+ 3 1
2
REV
VM1 1 2
ATTACH SOL 4
4
TCU(EST-65) VM2 2
B
A
C
D
C
VMG1 3 BACKUP BUZZER 5
116 116
FWD
104
3 1 2 3
VMG2 4 START RELAY 6 2
X2
X1
AD5
AD4
AD6
AD1
AD3
ED1
ADM4 5 105
(F)
(R)
(N)
VP
FUEL HEATER 7
AD5
AD3
AD7
AD6
AD4
AD2
AD1
ED1
1
ADM3 6 GND 8
START KEY S/W
F
B1
B2
R
B3
N
B BR ACC R1 R2 C
A
A
B
B
C
C
D
D
ADM2 7
GLOW RELAY 9
VPS2 8
CS-15
CS-14
WIF SENSOR 10
GEAR SELECTOR S/W

AIP5 9
911
AIP2 10 HORN 11
STARTING CIRCUIT
ADM6 11 TILT SWITCH 12
1
VPS1 12
GND 13
VPS1 13
46
SD1 14 GND 14
24
GND
2
SDDK 15 15
47
EF5 16
25
103
103
48
ER3 17
3
EUPR 18 CN-36 FUSE BOX A
26
HORN/CAB TILT 10A
4
19
49
EF1
1
ED3 20
27
STOP LAMP 10A
2
50
ED10 21
5
CLUSTER/RADIO 10A
3
ED7 22 CN-11
28
10A
105
423 423 423 423 TCU B+

4
VPE1 23
51
VPE(B+) 1
ECU B+ 20A
5
VMGA1 24
29
2
CANF_H 25 OPSS B+ 5A
52
6
VPI(IG) 3
CANF_L -
30
26
7
CANF_T 27 ED10(PARKING) 4
8
10A
53
OPSS IG
8
VGS 28 ED9(INCHING) 5
31
CLUSTER/RADIO 10A
9
ED11 29
54
ED11(AUTO 1) 6 20A
FUEL HEATER
10
ED12 30
32
ED8(AUTO 2) 7 10A
ED13 31 ECU IG
10
11
55
ED3(AD3) 8 10A
33
AIP3 32 TCU IG
12
ADM8 33 ED1(AD1) 9
11
56
911 911
ADM7 34
34
ED6(N)
7-8
10
105
104
SD3 35
12
57
ED4(F) 11 CN-37 FUSE BOX B
SD4 36
35
ED5(R) 12 ALTERNATOR 10A
1
58
37
13
AU1
103
EU1 38 EU1(SENSOR) 13 HEAD LAMP 15A
36
2
ER1 10A
14
39 REAR WORK LAMP
59
AU1(SENSOR) 14
3
EF6 40
37
VMGA1(SENSOR) 15 TAIL/BEACON LAMP 10A
4
CN-3
3
EF2 41
15
60
EU2(SENSOR) 16 TURN LAMP 10A
5
EF3 42
38
103 BACK UP LAMP 10A
6
ED4 43
16
61
TILT ALARM 5A
7
ED8 44
39
VPI 45 WIPER MOTOR 10A
17
62
8
VMGA2 46 20A
40
AIR CON
9
CANB_H 47
18
63
-
10
GANB_L 48
41
ACCEL PEDAL 5A
11
106
ER2 49
19
64
141 START RELAY 10A
1
12
AIP7 50
42
AIP6 51
20
65
100
ADM1 52
43
35R
1
2
VPS2 53
66
21
3
AIP8 54
44
105
AIP4 55
22
67
100
101
101
CN-15 103
AIP1 56
45
ADM5 57
105
116
106
68
12V X 2
23
VPS1 58
BATTERY
1
2
- 59
CN-74
2
1
4
3
SD2 60
35B
M
R
L
5
B+
2
1
EU2 61
CR-23
B+
CN-45
CR-5
3W
EF4 62
3BY
CN-95
1.25B
CR-24
1 2 1
1.25BR
CN-80
3
ED1 63
141
ED5 64
M
2
GLOW RY
G
4
911
2
FUSIBLE LINK
U
ED2 65 3
~
RELAY
GLOW PLUG
1
ED9 66 116
911 4 4 3
ED6 67
START MOTOR
ALTERNATOR
NEUTRAL
MASTER SW
VPE2 68
468
35B
START RY
50D7EEL04
3. CHARGING CIRCUIT
When the starter is activated and the engine is started, the operator release the start switch to the ON
position. Charging current generated by operating alternator flows into the battery.
The current also flows from alternator to each electrical component through the fusible link(CN-60)
and the fuse box.
1) OPERATING FLOW
(1) Warning flow
Alternator[CN-74(L)] I/conn[CN-2(6)] Cluster charging lamp ON [CN-56(4)]
(2) Charging flow
Alternator[CN-74(B+)] Fusible link[CN-95] Starter[CN-45(B+)] Battery(+) terminal charging
I/conn[CN-3] Fuse box
2) CHECK POINT
Η - GND (Alternator B+)

ON ON Θ - GND (Start switch) 24V
Ι - GND (Cluster)
ö GND : Ground
ö Cautions
1. When using an arc welder, always disconnect the ground lead from the battery to prevent alternator
or battery damage.
2. Attach the welding ground clamp as close to the weld area as possible to prevent welding current
from damaging the bearings of the alternator.
3. Do not disconnect the battery when the engine is running. The voltage surge can damage the
diode and resistors in the electrical system.
4. Do not disconnect an electric wire before the engine is stopped and the switches are OFF.
7-9
CHARGING CIRCUIT
START KEY S/W 103 105

B BR ACC R1 R2 C 103
HT
OFF
FUSE BOX A
FUSE BOX B
ON
1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
ST
10A
10A
10A
10A
20A
10A
15A
10A
10A
10A
10A
10A
10A
10A
10A
10A
20A
10A
20A
5A
5A
5A
-
-
TAIL/BEACON LAMP
REAR WORK LAMP
CLUSTER/RADIO
CLUSTER/RADIO
HORN/CAB TILT
BACK UP LAMP
WIPER MOTOR
ALTERNATOR
FUEL HEATER
ACCEL PEDAL
START RELAY
TILT ALARM
HEAD LAMP
TURN LAMP
STOP LAMP
OPSS B+
AIR CON
OPSS IG
CS-2
ECU B+
CN-36
CN-37
TCU B+
ECU IG
TCU IG
2
1
1
2
103
114
CN-57
TURN LH 1
HIGH BEAM 2
TURN RH 3
WORK LAMP 4
OPS LAMP 5
T/M FAIL 6
OPSS BUZZER 7
WIF(CAN) 8
ENG.WARNING(CAN) 9
GND(SIGNAL) 10
PARKING 11
PREHEAT(CAN) 12
AIR CLEANER 13
E/G OIL PS(CAN) 14
BRAKE PRESS LOW 15
CN-74
FUEL WARMER 16
114
ANTI RESTART 17 2 R
115 U
1
FUEL EMPTY 18
CN-3 CN-15 103
L ~
BRAKE OIL LOW 19 103 103 3 G
2 B+
GND(SIGNAL) 20 101
1
ALTERNATOR
CN-56
KEY ON POWER 1
3 1 2
FUEL GAUGE 2
T/M TEMP GAUGE(CAN) 3 101
CN-95
115 1
CHARGING 4 100
2
ILLUMINATION 5
RX232C TX 6 FUSIBLE LINK
DOWNLOAD 7
106
CR-23
3W
CRUISE ENABLE 8 1 2 1
1.25BR
CAN HIGH 9 2
105 3BY
GND(BATT) 3
10 1.25B
4 4 3
BATT(+) 11
E/G TEMP GAUGE(CAN) 12 START RY
CRUISE SET/DEC 13
SPEED GAUGE(CAN) 14
INCHING 15
RS232C RX 16 CN-45
115
114
105
GND(RS232C) 17 M
106 M
CN-2
CRUISE RESUME/INC 18
100
10
11
12
1
2
3
4
5
6
7
8
9
CAN LOW 19
GND(CAN) 20 B+
ENG OIL PRESS.
BRAKE FAIL SW
CLUSTER START MOTOR

FUEL SENDER
AIRCLEAR SW
FUEL EMPTY
BRAKE SW
BRAKE SW
ALT "L"
ALT "I"
WTS
35R 35B 35B

-
-
115
114
BATTERY MASTER SW
12V X 2
50D7EEL05
7-10
4. PREHEATING CIRCUIT
Combustion chamber glow plugs are used in order to give satisfactory starting of low ambient
temperatures.
1) OPERATING FLOW
Battery(+) terminal Fusible link[CN-95] Alternator [CN-74(B+) I/conn[CN-3]
Fuse box A [CN-36(1)Ą (2)] I/conn[CS-2(1)] Start switch(B)
ö
When you turn the start switch to the ON position, the glow relay makes the glow plugs operated
and the glow lamp of the cluster turned ON.
Start switch ON [CS-2(1)]
Fuse box [NO.8Ą10] Fuel heater relay [CR-47(2), (3)Ą (4)] I/conn[CN-1(7)]
Fuel heater [CN-7] Start relay[CR-23]
Glow aux relay[CR-45(2)Ą (4)] I/conn[CN-1(9)]
2) CHECK POINT
Η - GND (Battery B+)

Ι - GND (Glow plug)
Stop HEAT 24V
Κ - GND (Glow relay)
Λ - GND (Start switch)
Μ - GND (Glow lamp)
7-11
CN-1
WIF IG 1
ST
ON
HT
OFF
- 2 CS-2
103
HORN B+ 3 1
ATTACH SOL 4 2
5
BACKUP BUZZER 5
START RELAY 6 2
211 211
FUEL HEATER 7 105
1
GND 8
START KEY S/W
B BR ACC R1 R2 C
113 113
GLOW RELAY 9
WIF SENSOR 10
HORN 11
TILT SWITCH 12
6
GND 13
GND 14
PREHEATING CIRCUIT
GND 15
103
103
CN-36 FUSE BOX A

HORN/CAB TILT 10A
1
STOP LAMP 10A

2
CN-6 CLUSTER/RADIO 10A

3
10A
105
1 TCU B+
4
2 ECU B+ 20A
5
3 OPSS B+ 5A
6
-
7
4
OPSS IG 10A
8
5
CLUSTER/RADIO 10A
9
CN-153 6
770 770 770 119 FUEL HEATER 20A
10
GLOW RELAY 70 7
76
10A
101
770A ECU IG
11
GLOW RELAY 71 8
TCU IG 10A
12
EARTH(SIGNAL) 72 9
103
EARTH(SIGNAL) 73
10
105
ECU RY.COIL 74
11 CN-37 FUSE BOX B
ECU RY.COIL 75
10A
CN-3
12 ALTERNATOR
ECU
7-12
1
+BF 76
13 HEAD LAMP 15A
2
ENG. CHECK LAMP 82
103
REAR WORK LAMP 10A
14
3
IDLE UP 88
TAIL/BEACON LAMP 10A
4
15
TURN LAMP 10A
5
97
16
70
BACK UP LAMP 10A
6
TILT ALARM 5A
7
EARTH
WIPER MOTOR 10A

8
AIR CON 20A

9
-
10
ACCEL PEDAL 5A
11
START RELAY 10A

12
106
1
100
CR-47
2
35R
1 1
1
2
119
2
119
105
3
RELAY
105
106
211
100
101
101
CN-15 103
4 4 3
G6
211
3
4
2
12V X 2
BATTERY
2
1
1
2
4
3
2
1
CN-7
CN-74
FUEL HEATER
35B
M
R
L
3W
B+
3BY
2
1
1.25B
B+
CN-45
1.25BR
CR-45
CN-95
CR-24 1 2 1
CN-80
3
4
2
119
M
2
GLOW RY
START RY
G
1
770
FUSIBLE LINK
U
3
FUEL HEATER
~
RELAY
GLOW PLUG
113
113
4 4 3
START MOTOR
ALTERNATOR
MASTER SW
GLOW AUX
35B
50D7EEL07
GROUP 3 COMPONENT SPECIFICATION
No Part name Qty Specification
12VÝ80AH
1 Battery 2 RC : 130min
CCA : 630A
2 Working lamp 1 24V, 70W
3 License lamp 1 24V, 3W x 2
24V, 25/10W (Stop/Tail)
4 Rear Combination lamp 2 24V, 25W (Turn)
24V, 25W (Back Up)
5 Head lamp 2 24V, 70W
6 Flasher lamp 2 24V, 25/10W
7 Glow relay 1 24V, 300A
8 Relay (4P) 4 24V, 20A
9 Relay (5P) 3 24V, 6A
10 Flasher Unit 1 85Ü10CM, (21W + 21W) x 2 + 3W x 2
11 Back buzzer 1 24V, 90Ü5dB, 60Ü10C/M
12 Horn 1 24V, 1.5A, 100 ~ 115 dB
Float indicate E 1/2 F
13 Fuel level sender 1 Resistance(ɮ) 105 32.5 5

0 0.5
Tolerance(ɮ) Ü2.5
Ç5 Ç0
14 Master Switch 1 24V, 180A
Direction 4.5A, Tail 5A
15 Combination Switch 1
Head 6A, Horn 4A
16 Brake Switch 1 24V, 50W
17 Working Lamp Switch 1 24V, 8A
18 Hazard Switch 1 24V, 8A
19 Beacon Inching 1 24V, 8A
20 Auto manual Switch 1 24V, 8A
21 Start switch 1 24V, 30A
22 Fusible link 1 24V, 45A
23 Start relay 1 24V, 300A
24 Seat switch 1 24V, 8A
25 Tilt switch 1 24V, 8A
26 Warning buzzer 1 24V, 200mA, 90Ü5dB (˶m)
7-13
GROUP 4 CONNECTOR DESTINATION
Connector No. of Connector part No.

number Type Destination
pin Female Male
CN-1 AMP 15 I/conn(Console harness-frame harness) 2-85262-1 368301-1
CN-2 AMP 12 I/conn(Frame harness-console harness) S816-012002 174657-2
CN-3 KET 1 I/conn(Frame harness-console harness) MG640944-5 MG650943-5
CN-6 AMP 16 I/conn(ECU harness) 368047-1 368050-1
CN-7 BOSCH 2 Fuel heater 1-928-402-404
CN-8 AMP 8 Transmission display 929504-3 -
CN-9 AMP 4 TCU service tool 174257-2 174259-2
CN-10 AMP 8 I/conn(Console harness-T/M harness) S816-008002 S816-108002
CN-11 AMP 16 I/conn(Console harness-T/M harness) 368047-1 S816-116002
CN-13 NMWP 8 HMC engine harness PB625-08027 -
CN-14 AMP 42 HMC engine harness 936421 -
CN-15 SMITOMO 2 Alternator (B+) 6189-0172 -
CN-17 AMP 12 Cabin S816-012002 -
CN-19 KET 2 Output check S814-002100 MG610320
CN-20 KET 4 Aircon harness MG641744-5 -
CN-21 AMP 6 Wiper motor 936257-2 -
CN-22 KET 2 Washer tank MG640605 -
CN-25 MOLEX 2 Horn 35825-0211 -
CN-26 KET 2 Tilt alarm S822-014000 S822-114000
CN-36 - - Fuse box 21HF-10500 -
CN-37 - - Fuse box 21HF-10500 -
CN-45 RING TERM 2 Start motor S820-308000 -
CN-50 AMP 68 Transmission control unit 963598-1 -
CN-51 AMP 6 Diagnostic 926682-3 -
CN-55 KET 14 OPS unit S814-014100 -
CN-56 AMP 20 Cluster 174047-2 -
CN-57 AMP 20 Cluster 175967-2 -
CN-65 KET 2 Back buzzer S822-014000 S822-114000
CN-74 KET 2 Alternator MG640188-4 -
CN-80 RING TERM 1 Glow plug S820-204000 -
CN-98 KET 2 Resistor DT06-3S-EP06 -
CN-113 AMP OPSS buzzer 21N4-01111 -
CN-131 AMP 2 Cut off sol 1(tilt) S816-002002 -
CN-144 AMP 6 Accelerator pedal S816-006002 -
CN-147 KET 2 Cabin tilting lamp MG640188-4 -
CN-151 AMP 34 ECU 1123337-1 -
7-14
pin Female Male
CN-152 AMP 35 ECU 1123338-1 -
CN-153 AMP 32 ECU 1123339-1 -
CN-154 AMP 35 ECU 1123340-1 -
CN-155 AMP 31 ECU 1123341-1 -
CN-156 MOLEX 16 ECU diagonostic 51115-1601 -
CN-157 KET 2 CAN MG651026(L) -
CN-169 DEUTSCH 4 RS232C DT06-4S-EP06 DT04-4P-E005
Switch
CS-2 KET 2 Start switch MG620181 MG620282
CS-5 KET 2 Horn switch S814-102100 -
CS-11 KET 4 Combination switch S810-004201 -
CS-12 KET 3 Combination switch S810-003201 -
CS-14 PACKARD 4 Gear selector switch 12010974 -
CS-15 PACKARD 4 Gear selector switch 12015797 -
CS-17 KET 3 Parking switch S810-003201 -
CS-23 SWF 10 Beacon lamp switch 593757 -
CS-41 SWF 10 Hazard switch 593757 -
CS-42 SWF 10 Inching switch 593757 -
CS-59 SWF 10 Auto manual switch 593757 -
CS-69 SWF 10 Rear work switch 593757 -
CS-72 KET 2 Tilt switch MG610320 -
CS-73 KET 2 Seat switch S810-002201 -
CS-77 SWF 12 Cabin tilting switch 593757 -
Lamp
CL-15 KET 6 Combination lamp-LH S814-006100 -
CL-16 KET 6 Combination lamp-RH S814-006100 -
CL-21 KET 2 License 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-23 KET 2 Start relay S814-002100 S814-102100
CR-24 KET 1 Glow relay S822-014000 -
CR-34 KET 6 Parking relay S810-006202 -
CR-35 KET 4 Back up relay S810-004201 -
CR-40 KET 6 Illumination relay S810-006202 -
CR-43 KET 4 ECU power relay S810-004201 -
CR-44 AMP 2 Cabin tilting relay 17435202 -
CR-45 KET 4 Glow aux relay S810-004201 -
7-15
pin Female Male
CR-47 KET 4 Fuel heater S810-004201 -
CR-50 KET 6 Tilt cut-off relay S810-006202 -
Sensor and pressure switch
CD-2 KET 3 Fuel sendor S810-003201 -
CD-3 DEUTSCH 2 Brake fail pressure - DT04-2P-E005
CD-4 AMP 2 Stop lamp switch 171809-2 -
CD-10 KET 1 Air cleaner switch ST730057-2 -
CD-27 AMP 2 Turbin speed input 963040-3 -
CD-38 - 2 Water separator - S816-102003
CD-71 AMP 6 Inching sensor 1-967616-1 -
CD-72 AMP 2 Gear train speed sensor 963040-3 -
CD-73 AMP 3 Output speed sensor 282087 -
CD-74 AMP 2 Engine speed sensor 963040-3 -
CD-80 PACKARD 2 KV Solenoid 12162197 -
CD-81 PACKARD 2 KR Solenoid 12162197 -
CD-82 PACKARD 2 KD Solenoid 12162197 -
CD-83 PACKARD 2 KE Solenoid 12162197 -
CD-84 PACKARD 2 KC Solenoid 12162197 -
CD-90 AMP 2 Temp sensor 963040-3 -
DO-01 - 2 Diode 21EA-50550 -
7-16
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).
7-17
SECTION 8 MAST
GROUP 1 STRUCTURE
1. 2 STAGE MAST(V MAST)
9
5
2
Outer master
Inner master 6 7
Lift cylinder
6
Lift cylinder
10
2 4
Carriage Drive axle
50D7EMS01
1 Outer mast 5 Lift chain 9 Chain sheave bearing

2 Roller bearing 6 Anchor bolt 10 Side roller bearing
3 Tilt cylinder pin 7 Side roller bearing
4 Mast mounting pin 8 Inner mast
8-1
2. 3 STAGE MAST(TF MAST)
11
Middle master 9
73
Outer master
10
11 2
4
Inner master 3
8 1
Tilt cylinder
10
9 Lift cylinder Lift cylinder
12
5
2
9
Free Lift
cylinder
4 6
10
13 3
Drive axle
2
4
Carriage
50D7EMS011
1 Outer mast 6 Mast mounting pin 11 Chain

2 Shim 7 Wear plug 12 Sheave bracket
3 Roller bearing 8 Middle mast 13 Inner mast
4 Side roller bearing 9 Sheave
5 Tilt cylinder pin 10 Anchor bolt
8-2
3. CARRIAGE, BACKREST AND FORK
1) HOOK ON TYPE(STD)
Hook on type fork Extension fork
50DS7EMS03
1 Backrest 4 Side roller

2 Carriage 5 Fork
3 Roller 6 Extension fork
8-3
2) SHAFT TYPE(OPTION)
1
5
Shaft type fork Extension fork
80D7MS02
1 Carriage & backrest 5 Side roller

2 Hanger bar 6 Fork
3 Fork retaining 7 Extension fork
4 Roller
8-4
GROUP 3 ADJUSTMENT
1. MAST LOAD ROLLER
1) INNER/OUTER MAST ROLLER CLEARANCE ADJUSTMENT
(1) Measure the clearance with the mast
overlap at near 480mm(19in). Outer mast
Inner mast
A A
(2) Shift the inner mast to one side to bring Bring into
contact
the side roller into contact with the outer
mast, and adjust the clearance between
the end of inner beam and the outside of
outer mast position on the opposite side to Side roller
Adjust bolt
the following value by adjust bolt.
This roller
ÂReference clearance A = 43.1mm
80D7MS04
(3) Distribute the clearance A equally to the

left and right. This roller
A A
(4) After the adjustment, check that the inner
Side roller
mast moves smoothly in the outer mast. Bring
into
contact
Adjust
bolt Inner mast
Outer mast
80D7MS05
8-8
2) CARRIAGE LOAD ROLLER
(1) Measure the clearance when the center of
the carriage upper roller is 100mm from
Carriage Outer mast
the top of the inner mast. plate Adjust
screw
(2) Measure the clearance at upper, middle
100mm
and lower rollers after loosen the adjust
Bring
screws from the side rollers. Shift the into
contact
carriage to one side to bring the side roller Carriage
into contact with the inner mast, and Side
measure the clearance between inner B roller B
face of the inner mast and carriage plate Inner mast

at the closest position on the opposite side 80D7MS06
to the following value by adjust screw.
ÂReference clearance B = 56.9mm
(3) Distribute the clearance B equally to the
left and right.
(4) After the adjustment, the carriage should
move smoothly along the overall mast
length.
8-9
GROUP 4 REMOVAL AND INSTALLATION
1. FORKS
1) HOOK ON TYPE
(1) Lower the fork carriage until the forks are
approximately 25mm(1in) from the floor. Backrest
(2) Release fork anchor pins and slide one fork
at a time toward the center of the carriage Anchor pin
where a notch has been cut in the bottom Carriage
plate for easy fork removal.
(3) Remove only one fork at a time.
ö On larger forks it may be necessary to use a Center notch
block of wood.
(4) Reverse the above procedure to install load Fork
D507MS08
forks.
2) SHAFT TYPE(Option)
(1) Lower the fork carriage until the forks are Fork retainer
(2) Release fork retainer and remove cover.
Hanger bar
(3) Slide one hanger bar at a time out of
carriage assembly. Cover
(4) Remove only one fork at a time. Bolt
ö On larger forks it may be necessary to use a Fork
block of wood.
(5) Reverse the above procedure to install load D507MS07
forks.
2. BACKREST(Hook on type)
1) Remove bolts securing backrest to fork
carriage. Lift backrest straight up and remove
from carriage.
2) Position backrest on carriage and lower in Backrest
place. Install and tighten bolts. Bolt
Carriage
D507MS09
8-10
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 inner mast upright until mast clears top of fork carriage. Move carriage to work area
and lower mast.
ö 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 parts.
(6) Reverse the above steps to reinstall.
ö Replace the split pin of chain anchor with new one.
2) SIDE ROLLER
(1) Remove carriage as outlined in the
Carriage load
carriage removal paragraph. roller bearing
(2) Loosen and remove nuts, adjust screws
and side rollers from carriage side plate. Carriage &
(3) Thoroughly clean, inspect and replace all backrest
worn or damaged parts.
(4) Reverse the above procedure to assem-
bly. Side roller
ö Adjustment
Â Once carriage is properly installed, D507MS10
loosen nuts and adjust screws, (if not

already done) allowing carriage to be
centered in the inner mast.
Â Adjust side roller by tightening screw until
side roller just makes contact with mast. Side roller
Back off approximately 1/10 turn on
screw and tighten nut to lock screw in
Backrest
place.
Â Run carriage up and down along the
inner mast to be sure the carriage has
Bolt
free movement and does not stick. Also, Carriage
make sure chains are properly adjusted. Carriage load
Refer to chain adjustment paragraph. roller bearing
50DS7EMS11
Make adjustment when necessary and
recheck operation of carriage.
8-11
3) CARRIAGE LOAD ROLLER BEARING
(1) Remove carriage as outlined in the Carriage load
roller bearing
carriage removal paragraph.
(2) Using the plier, remove retaining rings Retaining
from load roller bearing bracket. ring
(3) Using a plier, remove load roller bearings
from load roller bearing bracket.
ble. Refer to MAST ROLLER ADJUST-
D507MS12
MENT paragraph.
4. MAST LOAD ROLLER

1) 2 STAGE MAST(V MAST)
(1) Remove the carriage assembly and move
them to one side.
Chain
(2) Loosen and remove hexagon nuts and
screws securing lift cylinders to inner mast. Hexagon nut
(3) Loosen and remove hexagon bolts and
nuts securing lift cylinders to outer mast.
(4) Attach chains or sling to the inner mast Screw
section at top crossmember. Using an
overhead hoist, slowly raise the inner mast Lift
Mast load cylinder
high enough to clear lift cylinder. roller
(5) After lowering the lift cylinder rods, and Inner
mast
disconnecting lift cylinder hose, tilt the lift
cylinders(LH and RH) with ropes to the
outer mast. Side
(6) Using the overhead hoist, lower inner mast roller
until top and bottom rollers are exposed.
(7) Using a plier, remove load rollers from load
Mast load
roller bracket. Remove side rollers. roller
(8) Thoroughly clean, inspect and replace all Outer
worn or damaged parts. mast
(9) Reverse the above procedure to assemble.
Hexagon
Refer to MAST ROLLER ADJUSTMENT bolt
paragraph.
After completing all necessary steps for Hexagon
nut
(10) load rollers removal, use an overhead hoist
to remove sling or chain around upper
crossmember of the inner mast section.
Lift inner mast upright straight up and out of D507MS13
outer mast section.

Replace and reverse above procedure to
(11) install.
Make all necessary measurements and
(12) adjustments.
8-12
2) 3 STAGE MAST(TF MAST)
(1) Remove the carriage assembly and move
it to one side.
(2) Loosen and remove hexagon bolt secur- Mast load roller
ing bottom cylinder from outer mast.
(3) Loosen and remove set screws and nuts
securing lift cylinders to middle mast.
(4) Attach chains or sling to the inner and
Chain
middle mast section at top crossmember.
Using an overhead hoist, slowly raise the Inner
uprights high enough to clear lift cylinder. mast
(5) After lowering the lift cylinder rods, and
disconnecting lift cylinder hose, tilt the lift Set screw
cylinders LH and RH and tie them with
ropes to the outer mast.
Hexagon
(6) Using the overhead hoist raise inner and nut
middle masts. Place 4inch block of wood Free lift
cylinder Lift
under the free lift cylinder bracket of the cylinder
inner mast then lower mast sections(this
will create slack in the chains).
Middle mast
(7) Remove retaining rings securing chain
sheaves to sheave support brackets while
supporting chains, remove chain sheaves Side roller
and let chains hang free. Lift

The upper outer and lower middle mast cylinder
rollers and back up liners are now
exposed. Mast load roller
(8) Using a plier, remove load rollers from Mast load roller
load bracket. Remove side rollers from
mast. Hexagon
(9) Attach chains or sling to the middle mast bolt
section at top crossmember. Using an Hexagon Outer
nut mast
overhead hoist, slowly raise the middle
mast until top and bottom rollers are
exposed.
(10) Using a plier, remove load rollers from
roller bracket.
(11) Thoroughly clean, inspect and replace all
D507MS014
ble. Refer to MAST LOAD ROLLER ADJ-
USTMENT Paragraph.
8-13
5. CHAIN
1) CHAIN SHEAVE
(1) Place a sling around carriage and attach Chain Outer mast
to an overhead hoist. Lift carriage high
enough so that the tension on the chain Sheave
over sheaves is relieved after the carriage Inner mast
is blocked. Position wooden blocks under

the carriage and lower it.
(2) Remove the split pin securing the chain Anchor
bolt
anchor pins and discard. While
supporting the chains, remove the chain
anchor pins and drape the chain over the
carriage.
(3) Remove retaining ring securing sheaves
to sheave support. Remove sheaves with
bearings.
(4) Remove bearing retaining ring from
Carriage
sheave and press bearings from sheaves.
worn or damaged parts. D507MS15
(6) Reverse the above to assemble and

install. Use new split pins in chain anchor
pins.
2) Rear chain sheave(TF mast)
(1) Raise and securely block carriage and
inner mast section.
Chain Middle mast
(2) Remove the split pin securing the chain
anchor pins and discard. Anchor
bolt
(3) Remove chains.
(4) Remove retaining ring securing chain Chain
sheaves to sheave support. Pry off
sheaves with bearings.
(5) Remove bearing retaining ring from
sheave and press bearings from sheaves.
(7) Reverse the above procedure to assemble
and install. Use new split pins in chain
anchor pins.
Carriage
Free lift cylinder Inner mast
D507MS016
8-14
3) Sheave support(TF mast)
(1) Remove the carriage assembly and move to one side.
(2) After removing bolt to securing sheave support assembly to free lift cylinder.
Attach a sling to the sheave support assembly. Using an overhead hoist, lift support assembly
straight up and off of free lift cylinder. Move assembly to work area.
(3) Remove retaining ring securing sheave to sheave support.
(4) Remove bearing retaining ring from sheave and press bearings from sheaves.
(5) Thoroughly clean, inspect and replace all worn or damaged parts.
(6) Reverse the above procedure to install.
4) Rear chain(TF mast)
(1) Remove the carriage assembly and move to one side. Refer to carriage removal and installation.
(2) Raise and securely block truck approximately 6 inches from the floor.
(3) Using a sling or chain around inner mast section attached to an overhead hoist, slowly raise inner
mast until there is enough slack in the chains to remove them. Block inner mast section.
(4) Remove split pins and chain anchor pins securing chains to chain anchor(part of inner mast).
(5) While supporting the chains, remove split and chain anchor pins securing chains to chain anchors
attached to outer mast section.
(6) Remove chains.
(7) Reverse the above to assemble and install. Use new split pins in chain anchor pins. Refer to this
section for Load chain lubrication and adjustment.
5) Carriage chain
(1) Place a sling around carriage front plate and attach to an overhead hoist. Lift and secure carriage
high enough so that split and chain anchor pins on carriage can be easily be removed. Remove
chain anchor pins from carriage and drape chains out over carriage.
(2) Place a wooden block under the carriage and lower the carriage on the block.
(3) While supporting the chains, remove split pins and chain anchor pins from chain anchors.
(4) Remove chains and wash them with solvent. Refer to this section for Load chain inspection and
maintenance.
(5) Reverse the above procedure to assemble and install. Use new split pins in chain anchor pins.
Refer to this section for Load chain lubrication and adjustment.
6) Load chain inspection and maintenance
After every 200 hours of truck operation, lift chains should be inspected and lubricated inspect for
the following chain conditions :
(1) Wear
As the chain flexes on and off the sheaves, 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 out the worn section and splicing in a
new piece. If part of the chain is worn, replace all the chains on the truck.
8-15
(2) Rust and corrosion
Chains used on lift trucks are highly stressed precision components. It is very important that the
“as-manufactured” ultimate strength and fatigue strength be maintained throughout the chain
service life. Corrosion will cause a major reduction in the load-carrying capacity of lift chain or
roller chain because corrosion causes side plate cracking.
(3) Cracked plate
The most common cause of plate cracking is fatigue failure. Fatigue is a phenomenon that affects
most metals and many plastics. After many repeated heavy loads, the plates may crack and the
chains will eventually break. Fatigue cracks are almost always found through the pitch holes
perpendicular to the pitch line. Contrast this failure mode to the random failures caused by stress-
corrosion cracking. If cracks are present, replace all the chain on the truck. Noise in the chain
indicates that the plate is on the verge of cracking and will be failed before long.
(4) Tight joints
All joints in lift chain should flex freely. Tight joints resist flexure, increase internal friction, thus
increasing chain tension required to lift a given load. Increased tension accelerates wear and
fatigue problems.
Tight joints in lift chains can be caused by :
ÂBent pins or plates.
ÂRusty joints.
ÂPeened plate edges.
Oil rusty chains and replace chains with bent or peened components.
(5) Protruding or turned pins
Heavily loaded chains operating with lube generate tremendous friction between pins and plates.
In extreme cases, the frictional torque in the joint can actually turn pins in the press-fit outside
plates. If chain is allowed to operate in this condition, the pins slowly work out of the chain
causing chain failure. Turned pins can be quickly spotted because the flats on the V heads are no
longer in line. Chains with turned or protruding pins should be replaced immediately. Do not
attempt to repair the chain by driving pins back into the chain.
(6) Chain side wear
A wear pattern on pin heads and outside plates indicates misalignment. This condition damages
chain and sheaves as well as increasing internal friction in the chain system.
(7) Chain anchors and sheaves
An inspection of the chain system includes a close examination of chain anchors and sheaves.
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. Sheaves with badly worn flanges and outside
diameter should be replaced. Heavy flange wear indicates chain misalignment.
8-16
(8) Chain wear scale
The chain can be checked for wear or stretching with the use of a chain wear scale. Stretching of
a chain is due to the elongation of the pitch holes and wearing of the pin O.D. The greatest
amount of stretching occurs at the areas of the chain that flex over the sheaves most frequently.
Check the chain at this point with a scale. The wear scale has instructions printed on the sides for
use in determining chain stretch and are as follows :
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
(1) Lubrication
The most important consideration in field maintenance of lift chains is lubrication. Hard working,
heavily loaded chains cannot be expected to give satisfactory wear life without scheduled periodic
re-lubrication. Like all bearing surfaces, the precision manufactured, hardened steel, joint-wearing
surfaces require a film of oil between mating parts to prevent rapid wear. Oil must penetrate the
chain joint to prevent wear. Applying oil to external surfaces will prevent rust, but oil must flow into
the live bearing surfaces for maximum wear life. Frequency of re-lube will vary with operating
conditions and environment, the best estimate of lube period is 200 hours. Trucks parked
outdoors or trucks in extremely severe service, may require more frequent re-lube to maintain an
oil film on all chain surface.
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).
(2) Replacement
Replace chains as a pair. It will be virtually impossible to maintain uniform loading between the
strands if a new chain is put into service opposite an old chain. The joints in the old chain will be
greater than that on the new chain, greatly complicating the problem of maintaining equal chain
tension. The new chain will wear more slowly causing it to bear the major portion of the load
resulting in premature wear and fatigue failure. Don’t steam clean or decrease new chains.
The manufacturer’s grease is effective in reducing wear and corrosion. If the original factory lube
is dried out or wiped off, soak the new chain in heavy engine oil for at 1/2 hour prior to installing on
truck. After the old chains have been stripped from the mast, very carefully inspect chain anchors
and sheaves. 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.
8-17
(3) 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.
(4) 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.
8-18

80D-7E Hyundai Shop Manual

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What are the main sections covered in the manual?

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What should be done to maintain lift chains?

What should be done to maintain lift chains?

FOREWORD

2. Convert 550mm into inches.

Millimeters to inches ; 1mm = 0.03937 in

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

0 0.039 0.079 0.118 0.157 0.197 0.236 0.276 0.315 0.354

Kilogram to Pound 1kg = 2.2046lb

0 2.20 4.41 6.61 8.82 11.02 13.23 15.43 17.64 19.84

0 0.264 0.528 0.793 1.057 1.321 1.585 1.849 2.113 2.378

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

0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

7.2 14.5 21.7 28.9 36.2 43.4 50.6 57.9 65.1

14.2 28.4 42.7 56.9 71.1 85.3 99.6 113.8 128.0

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

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

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

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

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

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

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

SECTION 2 REMOVAL AND INSTALLATION OF UNIT

SECTION 3 POWER TRAIN SYSTEM

SECTION 4 BRAKE SYSTEM

SECTION 5 STEERING SYSTEM

SECTION 6 HYDRAULIC SYSTEM

SECTION 7 ELECTRICAL SYSTEM

Careless performing of the easy work may

Â Wear well-fitting helmet, safety shoes and

Â Flames should never be used instead of

Â Exhaust gas is dangerous. Provide adequate

Â When working on top of the machine, be

Â Hand a caution sign in the operator's compartment

When inspecting the engine is running parts, or

Â When working with others, choose a group

Â Unless you have special instructions to the

Â Always remember that the hydraulic oil circuit

1 Mast 6 Forks 11 Bonnet

Model Unit 50D-7E 60D-7E 70D-7E 80D-7E

Model  HYUNDAI D4DD-C7

(2) MAIN PUMP

Item Unit Specification

Type  Fixed displacement gear pump

(3) MAIN CONTROL VALVE

Item Unit Specification

Model F&S 300*16/4/-1(ZF SACH)

Model  HYUNDAI D4DD-C7

(2) MAIN PUMP

Item Unit Specification

Type  Fixed displacement gear pump

(3) MAIN CONTROL VALVE

Item Unit Specification

Model F&S 300*16/4/-1(ZF SACH)

NO ITEMS SIZE kgfÂm lbfÂft

1 Engine mounting bolt, nut M16Ý2.0 7.5 54

(2) Fine thread

Model HYUNDAI D4DD-C7

Type Fixed displacement gear pump

Model HYUNDAI D4DD-C7

Type Fixed displacement gear pump