110 160D 7E+Service+Training. Forklift

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1
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Contents.
A. Machine specifications and features Page: 2-9

B. Transmission (ZF3WG161) Page: 10 - 27
C. Front axle (Kessler D81PL478) Page: 28 - 54
D. Brake system Page: 55 - 68
E. Steering system Page: 69 - 74
F. Hydraulic system Page: 76 - 84
G. Cooling system Page: 85 - 90
H. Electric system Page: 91 - 118
I. Engine Page: 119 - 133
J. Mast Page: 134 - 136
K. Maintenance Page: 137 - 140
L. Air-conditioning Page: 141 - 174
2
3
110/130/140/160D-7E: Machine specifications.
Description 160D-7E
Cummins (High pressure

Maker common rail)
Model QSB6.7
Fuel Consumption 110/120: 11l/h,
(45VDI cycles) 140/160: 11.5l/h
EMISSION Tier-3
Sound at operators ear level 76db(A)
Rated gross horse power 162PS( 119Kw)

(ps/rpm) @ 2,200RPM
Max. Torque
74.6/1,400
(kg-m/rpm)
Piston Displacement
6,700
(cc)
4
Model Unit 110D-7E 130D-7E 140D-7E 160D-7E

Capacity kg 11,000 13,000 14,000 16,000
Load center mm 600 600 600 600
Lifting height (Stand.) mm 3,305 3,305 3,305 3,305
Free lift mm 0 0 0 0
mm/se
Load 440 430 360 350
c
Lifting
speed
mm/se
Unload 510 510 450 450
Fork c
P
E mm/se
R Load 510 510 430 430
Lowering c
F
O speed
mm/se
R Unload 460 460 390 390
c
M
A L ×W×T mm 1350x200x75 1350x200x85 1350x200x85 1350x200x90
N
S Tilt angle
Degree 15/12 15/12 15/12 15/12
(forward/backward)
Mast
Max height mm 4,765 4,765 5,010 5,010
Min height mm 3,150 3,150 3,400 3,400
Travel speed(Unload) km/hr 35.0 34.8 33.8 33.6
Gradeability(Load) % 39.2(1mph) 33.2(1mph) 30.0 (1mph) 27.5(1mph)
←
Body
Min turning radius mm 4,080 4,080 4,580
Traction (Load) kg 9,267(1mph) 9327 (1mph) 9325 (1mph) 9359(1mph)
5
Model Unit 110D-7E 130D-7E 140D-7E 160D-7E

WEIGHT (Unload) kg 15,797 16,503 18,378 19,235
29,350 / 32,199 /
Front Load/Unload kg 23,844 / 7,704 26,702 / 7,605
9,283 9,241
Rear Load/Unload kg 2,625 / 7,765 2,802 / 8,898 3,028 / 9,095 3,036 / 9,994
Tipping Load kg 16,619 18,974 20,988 22,982

G
LENGTH TO FORK FACE mm 4,340 4,345 4,900 4,905
E
N Fork Overhang mm 755 760 830 835
E
R OVERALL WIDTH mm 2,450 2,450 2,497 2,497
A
L HEADGUARD HEIGHT mm 2,900 2,900 2,900 2,935
GROUND
mm 270 270 270 270
CLEARANCE(MAST)
WHEEL BASE mm 2,900 2,900 3,300 3,300
Front mm 1,842 1,842 1,842 1,842

Tread
Rear mm 1,910 1,910 1,955 1,955
Cummins Cummins Cummins Cummins

E Model
QSB6.7 QSB6.7 QSB6.7 QSB6.7
N
G
Rated gross horse power ps/rpm 162 / 2,200 162 / 2,200 162 / 2,200 162 / 2,200
I
N
E kg.m/r
Max. torque 74.6 / 1,400 74.6 / 1,400 74.6 / 1,400 74.6 / 1,400
pm
T
Maker ZF (3WG161) ZF (3WG161) ZF (3WG161) ZF (3WG161)
M
Tire Front/Rear 10.00-20-16 10.00-20-16 12.00-20-18 12.00-20-18
6
110/130/140/160D-7E: Machine features.
Hyundai
Function
160D-7E
1) ESL (Engine Start Limit) ○

2) Rear View Camera ○
3) Cruise Control ●
4) Hands Free ○
5) Combination Key (200Type) ●
6) CDMP3 Player ●
7) Electric Heated Seat ○
8) 12V / 24V Power Outlet ●
9) Anti-Restart function ●
10) Auto Parking function ●
11) Operator sensing system ● (Auto)
12) Low Idle RPM adjust ●
● = standard / ○ = Option
7
Start to know your machine.
8
Start to know your machine.
Right turning pilot lamp

Transmission Temp. lamp
9
10
Transmission 3WG161.
ZF3WG161 3 Speed
Automatic
Transmission.
Transmission diagnostic
display on dashboard.
Detailed disassembly > assembly procedures and complete error

code lists can be found in our online service manual on CERES.
11
Transmission 3WG161: layout.
11 = Wiring
14 = inductive transmitter speed central gear train
15 = inductive speed engine
16 = inductive transmitter speed turbine
17 = temperature measuring point behind the converter
18 = plug connection on the electro hydraulic control unit
19 = Cable to filter contamination switch

20 = Cable to speed sensor output
21 = Cable from angle sensor/inch-sensor
22 = Transmission
2 = Display
3 = Gear selector DW - 3
4 = Power supply connection Replace transmission oil every 1000h
5 = Switch for enable inched (Option) SAE10W30 – SAE15W40 (+/- 16L)
6 = Selection Switch: Man./Auto1/Auto2
9 = TCU(EST-37A)
12
Transmission 3WG161: Hardware layout.
E
AN = Input / engine
N KV = Clutch forward
G KR = Clutch reverse
I K1 = Clutch 1st speed
K2 = Clutch 2nd speed
N K3 = Clutch 3rd speed/output
E PTO = Power take-off / hyd. pump
S
H
A
F
T
13
Transmission 3WG161: Hydraulic diagram.
NFS: Follow-on slide

D: Vibration damper
B: Orifice
P1: Not used
P2: Proportional valve>KR
P3: Proportional valve>K1
P4 Proportional valve>K3
P5 Proportional valve>KV
P6 Proportional valve>K2
Y1~Y6 Solenoids
14
Transmission 3WG161: Transmission control valve
1. Pressure reducing valve(9bar)

2. Main pressure valve (16 + 2bar)
3. Housing
4. Plug (cable harness)
5. Cover
6. Valve block
7. Intermediate plate
8. Duct plate
9. Vibration damper
10. Follow - on slide
11. Pressure regulator
SOLENOIDS Y1 to Y6:
- Resistance : 19Ω (±10%) @ 20°C
- Current : 100-500mA
- Pressure Range: 0.8 - 8.3 bar
15
Transmission 3WG161: Transmission control valve
ar
11B
s. ) :
g pre
enin
/C (op
T
ore
Bef
Main Pres.: 16Bar
K2: 16Bar Not Applied
KV: 16Bar KR:16Bar
K3: 16Bar K1:16Bar

SUMP TEMP SENSOR IS
INTEGRATED INSIDE THE
T/M CONTROL VALVE
RESISTANCE
1000 Ω - 1500Ω
CHECK
TCU HARNESS PINS 46 & 39
16
Transmission 3WG161: T.C.V. theory.
- The transmission pump, necessary for the oil supply of the converter, and for the transmission control, is sitting in the transmission
on the engine-dependent input shaft.
- The feed rate of the pump is Q = 85ℓ/min, at nMotor = 2000 min -1
- This pump is sucking the oil via the coarse filter out of the oil sump and delivers it via the fine filter, the filter can also be fitted
externally from the transmission to the main pressure valve.
- If because of contamination, respective damage, the through-flow through the fine filter is not
ensured, the oil will be directly conducted via a filter differential pressure valve(bypass valve △p = 5.5+3bar) to the lubrication. In this
case, an error indication is shown on the display.
- The five clutches of the transmission are selected via the 6 proportional valves P1 to P6(P1 will not be under current at the 3-speed
version, i.e. without function).
- The proportional valve(pressure regulator unit) is composed of pressure regulator(e.g. Y6), follow-on slide and vibration damper.
- The control pressure of 9 bar for the actuation of the follow-on slides is created by pressure
reducing valve. The pressure oil(16+2bar) is directed via the follow-on slide to the respective clutch. Due to the direct proportional
selection with separated pressure modulation for each clutch, the pressure to the clutches, which are engaged in the gear change, will
be controlled. In this way, a hydraulic intersection of the clutches to be engaged and disengaged becomes possible. This is creating
spontaneous shifting without traction force interruption.
- At the shifting, the following criteria will be considered :
- Speed of engine, turbine, central gear train and output.
- Transmission temperature.
- Shifting mode(up-,down-, reverse shifting and speed engagement out of Neutral).
- Load condition(full and part load, traction, overrun inclusive consideration of load cycles during the
shifting).
- The main pressure valve is limiting the max. control pressure to 16+2.5bar and releases the main stream to the converter and
lubrication circuit. In the inlet to the converter, a converter safety valve is installed which protects the converter from high internal
pressures(opening pressure 11+2bar). Within the converter, the oil serves to transmit the power according to the well-known
hydrodynamic principe (See Chapter torque converter page 3-3).
- To avoid cavitation, the converter must be always completely filled with oil. This is achieved by converter pressure back-up valve,
rear-mounted to the converter, with an opening pressure of at least 4.3+3bar.
- The oil, escaping out of the converter, is directed to the oil cooler.
- From the oil cooler, the oil is directed to the transmission and there to the lubricating oil circuit, so that all lubricating points are
supplied with cooled oil.
- In the electro hydraulic control unit are 6 pressure regulators installed.
17
Transmission 3WG161: sensors and checkpoints.
18
Transmission 3WG161: sensors and checkpoints.
19
Transmission 3WG161: sensors location.
3)
-7
D
Oil filter pressure switch (CD-75) (C
e r
itt
sm
an
tr
d
ee
Sp
Tr
an
)
27
sm
D-
itt
Bar
(C
3-3
er
: 4,
in
m
T/C
te
d
rp
ehin
r
eb
na
e
ur
in
ss
ls
Pre
rb
pe
tu
ed
re
in
itt
Inductive transmitter rpm engine (CD-74)
pu
sm
tr
an
pm
tr
(C
e
iv
D-
ct
72
du
Temperature sensor behind converter (CD-29)
In
20
20
Transmission 3WG161: sensors tests.
21
Transmission 3WG161: gear selector (DW-3).
= 1st speed forward

= 2nd speed forward
= 3nd speed forward
Gear
selector TCU
22
Transmission 3WG161: AEB calibration.
What: - It is the abbreviation for Automatische Ermittlung der Befüllparameter in German:

(Automatic measurement of filling parameters). (Part number: 0501-211-778)
- To minimize the shifting shock which is caused by the clearance of parts (discs) in T/M.
- To keep the best shifting performance in compensation for its clearance by checking the
clearance of clutch discs.
How: - When hydraulic oil has filled the clutches, TCU will checks the signal of speed sensor and
calculates the clearance among all clutches and compensate this by adjusting the filling time and
pressure of clutches.
Procedure: (Recommended to execute after every 1000h of application).
1. Start engine after parking the machine on flat ground and blocking wheels.
2. Heat up T/M oil temperature until it reaches 75-80 degree, apply the parking brake and shift
the gear into neutral position to keep the machine at low rpm.
3. Connect the AEB starter to T/M controller.
4. Push the button on the AEB starter over 3 seconds.
5. Confirm the status of AEB from the display.
-Normal operation shows “ST,KR,KV,K1,K2,K3” orderly for 3-5minutes.
-After the successful completion, it displays “OK”.
-With a new controller, it may display “F6” error code before AEB, but after AEB, it will disappear.
6. In case of abnormal running, it may display “STOP” with appropriate error code.(see next page)
7. After troubleshooting, start the machine again and repeat above procedure.
23
Transmission 3WG161: inching sensor adjustment.
1. Start engine after parking the machine on flat floor and

blocking wheels.
2. Release parking brake and keep neutral gear selected.
3. Regulate the inching sensor linkage in a way the inching
sensors output voltages are as next:
- Pedal not operated (1±0.1V),
- Pedal operated (3.5±0.1V))
4. Stop the engine and leave the KEY “ON”.
5. Release parking brake, keep neutral gear selected.
6. Connect the AEB STARTER to the T/M controller.
7. Push AEB STARTER over 3 seconds.
- If display shows "▼IP", Step on the pedal fully.
- If display shows "▲IP", release "OK"
8. After the successful completion, it displays "OK".
9. In case of any abnormalities, display will show "STOP" with
the appropriate error code.
10. After troubleshooting, start the machine again to repeat
above procedure.
11. Above works are to be done with the parking brake
released, so machine's wheels must be
blocked for safety.
12. Adjust bolt(3) so that brake pedal interconnects with
inching pedal at an inching pedal stroke of 22mm
24
Transmission 3WG161: AEB / inching error codes.
A.E.B.
Inching sensor.
25
Transmission 3WG161: error display and code list
A detailed list of all possible transmission error

codes can be found in the online service manual
26
Transmission: maintenance recommendations.
-Initial transmission oil + filter replacement after 100H.
- Next each 1000H, replacement of transmission oil + filter (SAE10W-30) + AEB test!!!
27
28
Front Axle: layout.
1 2 1
3 3
Service wet brake (1) Drive assembly (2) Hub + final drive assembly (3)
29
Front axle: Final drive + Planet gear.
300. Planetary housing

304. O-ring
306. Sealing ring
307. Screw plug
308. Sealing ring
310. Adjusting screw
311. Slotted nut
312. Hexagon socket screw
314. Sun gear
316. Circlip
320. Thrust ring
322. Planetary gear
324. Thrust washer
329. Needle bearing
331. Planetary pin
333. Locking pin
335. Ring gear
336. Ring gear carrier
337. Retainer
338. Hexagon socket screw
340. O-ring
30
31
32
Front axle: Final drive shaft adjustment.
- The axial clearance between axle shaft respective

universal joint and adjusting screw must be 0.3~0.7mm.
- The adjustment has to be made by screwing in the
adjusting screw until it touches the axle shaft respective Drive shaft
universal joint.
- Back-off the adjusting screw 72°~170 from the
tightened position(this corresponds to about 0.3~0.7mm
axial clearance).
- Secure the adjusting screw and the counter nut with
Loctite 270.
* When tightening the counter nut(29), hold the adjusting
screw unconditional, to prevent turning of the adjusting
screw.
33
Front Axle: Wet Brake System (Service brake).
1. Brake carrier 12. Breather

2. Brake housing 13. Sealing ring
3. Piston 14. Sealing ring
4. Inner disc 15. Spring
5. Outer disc 16. Screw
6. O-ring 17. Seal ring
7. Screw 18. Screw plug
8. Screw plug 20. Face seal
9. Seal ring 22. Tube
10. Seal ring 23. O-ring
11. Connection socket
Brake system cooling outlet
Pressure to brake discs
Brake system cooling inlet
34
Wet Brake System disassembly / assembly.
35
36
37
38
39
40
41
42
43
44
45
46
Adjustment of wheel bearings:
1. The temperature of the axle parts should be between 0 and +20。C at the
bearing adjustment.
2. Screw on the wheel safety nut(Loctite-respective Molykote-using see
below) and adjust and secure as follow :
3. Screw on the wheel safety nut and tighten it with a 1.5 to 2 times higher
tightening torque than the finish tightening torque. During the tightening,
turn the wheel hub a few times and knock it with a plastic hammer. 4. Un-
tighten the wheel safety nut(about 180。back rotation), then tighten the
wheel safety nut to the tightening torque of 450Nm, during tightening turn
the wheel hub also a few times, if there is no possibility for securing, the
wheel safety nut has to be turned back to next securing possibility.
47
48
49
50
Front axle: Differential structure.
412. Bearing bushing

413. Hexagon screw
414. Hexagon screw
415. Tapered roller bearing
417. Differential carrier
418. Hexagon screw
419. Setting ring
420. Setting ring
421. Lock plate
422. Hexagon screw
423. Hexagon screw
400. Differential & carrier
425. Hexagon screw
401. Drive pinion
427. Screw plug
402. Ring gear
428. Sealing ring
403. Differential housing
404. Differential housing
405. Differential spider
440. Radial seal ring
406. Differential side gear
444. Drive flange
408. Differential pinion
445. Adjusting nut
409. Disk
411. Thrust washer
51
Front axle: Differential adjustments.
52
Front axle: Differential adjustments.
53
Front axle maintenance recommendations.
-Initial front axle + final drive oil replacement after 100H.
- Next: each 1000H, replacement of final drive, front axle and brake system cooling oil !!!
Front axle oil fill plug

19L SAE80W-90/ API
Front
GL5
axle oil
level
check
plug
Final drive Final drive filling position

Front
draining 1.7L (LH/RH) SAE80W/90
axle oil
position API GL5
drain
plug
After draining brake system

cooling, refill in 3 stages:
1.Fill cooling oil tank with 10L
of hydraulic oil (VG46).
2. Add 1L Addictive oil:
Lubrizol LZ9990A (P/N:
1900LZ9990AC)
3. Add another 10L of
hydraulic oil (VG46)
Brake system cooling
drain plug at the
backside
54
55
Brake system: layout.
6
9
A. Cut Off valve.
4. Accumulator from brake system.
5. P/SW TCU > rear brake lamps (5Bar +/-1).

7
0 6. P/SW switches parking (PS1) (95Bar +/-5)
6. P/SW charging (PS) (95bar +/-5).
7. Line filter on “PP” of cut off valve.
21. Pressure check port (0 > 105Bar)
64. Line filter on pressure line “P”

7
1
67. Accumulator on RCV pilot pressure .
69. Brake valve inside cabin.
70. Brake pump on Engine PTO.
71. To hand brake cylinder on external disc.
56
Brake system: Hydraulic diagram.
35
1. Main pump : Mounted on transmission PTO.
36
2. Brake pump : Mounted on engine PTO.
5. Cut off valve : Underneath cabin.
8. Brake valve : Brake pedal inside cabin.
9. Line filter : Filter to MCV. On cut off valve.
10. Safety valve : To cut pilot pressure to RCV.
11. RCV : Remote Control Valve (levers).
17. Pressure switch : To TCU > rear brake lamps.
18. Pressure switch : Accumulator charging switch.
19. Pressure switch : Parking pressure switch.
20. Accumulator : Engine OFF brake accumulator.
19 21. Accumulator : Pilot pressure to RCV accu.
22. Line filter : Pressure line to cut OFF valve.
23 Strainer : In hydraulic tank. (suction).
24 Return filter : In hydraulic pressure line.
31 Fan drive motor : Behind the coolers (160Bar).
32 Orifice : On fan motor > oil to cooler.
* 33 Oil cooler : Hydraulic oil cooler.
34 Hydraulic oil tank :Hydraulic oil reservoir.
35 Service brake : Wet discs in front axle.
36 Hand brake : Disc on output shaft front axle
* Pressure to RCV : 30 – 40Bar
57
Brake system components: Brake valve.
B
T
L
B
P
R 5 Bar+/-1
CD-4
Cable
135/232
B
L
Brake pressure
supply from cut
off valve
105Bar
B
R Hand brake pressure from
cut off valve (105Bar)
Front axle
58
Brake system components: Brake valve.
Purpose: The purpose of the brake valve is to proportionally increase and decrease the
braking pressure to the brake discs when the brake pedal is actuated.
Ready position:
A connection is established between port (BR) and port (T) so that the wheel brakes port
(BR) becomes pressure less via the returns ports (T).
Partial braking:
When the brake valve is actuated, an amount of hydraulic pressure enters trough (P).
The main spring(6) beneath pedal plate(12) is designed in such a way that the braking
pressure changes depending on the pedal’s angle. In the lower braking pressure range,
the machine can be stopped proportionally.
When the braking process is started, the spool (2) is mechanically actuated via the main
spring (6). As spool (2) move downward, it will first close return (T) via the control
edges, thus establishing a connection between accumulator ports (P) and ports (BR) to
the wheel brake cylinders. The applied foot force determines the output braking pressure.
The control spool (2) is held in the control position by the force applied (Spring assembly
above the spool).
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). Return (T) is
closed at this point. When the braking process is ended, a connection is once again
established between brake cylinder port (BR) and return port (T), closing accumulator
ports (P).
Limiting the braking pressure: (105Bar).

Pedal restriction bolt(19) on base plate below pedal is used to limit the braking pressure.
+/- 35° angle.
Installation requirements:
Return line (T) must be connected directly to the tank.
The connecting lines must be installed is such a way as to permit proper bleeding.
59
Brake system components: Cut off valve.
7
8
1. Manifold. 170Bar
2. Parking brake solenoid valve (CN71). 4 8
3. Parking brake solenoid coil.
4. Check valve in “P” line.
5. Check valve in RCV line.
2 150Bar
6. Brake system Cut-off valve. to
7. RCV Cut –off valve.
4 120Bar
8. Brake Relief valve (170Bar).
9. RCV Relief valve (60 bar). 6
B1. Pressure line to brake valve. 40Bar
T/T1/T2. Return lines. 5 to
P. Pressure line from brake pump.
7 30Bar
PP. Pilot pressure line to RCV.
B. Pressure line to parking brake.
PS. To accumulator charging pressure
switch.
9 60Bar
PS1. To parking brake pressure switch.
A3. Brake system accumulator.
A4. RCV pilot pressure accumulator.
60
Brake system components: Cut off valve.
Pressure line RCV system Brake system Brake fail Parking brake Pilot pressure
“P” check cut off valve cut off valve pressure pressure to RCV+/-
point 170Bar 40-30Bar 150-120Bar switch (PS) switch (PS1) 40Bar
Brake Brake
RCV system Steering
Pilot system pressure Parking brake pressure to
relief valve pressure
accumulator relief valve solenoid. front axle
60Bar 175Bar.
170Bar 105Bar.
61
Brake system components: Handbrake system.
The two identical brake pads can slide freely on the

guide bolt, which are fastened in the housing. The
guide bolts are guided in an additional brake anchor
plate which in turn is screwed onto the vehicle, i.e.
its axle.
On actuation, the brake generates a clamping force
at the brake lining pads, which cause a tangential
force/braking moment to be generated at the brake
disk, the extent of which depends on the
coefficients of friction generated by the linings. The
clamping force is generated by the bank of cup
springs, during which the piston is moved together
with the adjusting screw, the thrust bolt and the
brake pad towards the brake disk.
When the brake pad comes into contact with the
brake disk, the reaction force shifts the housing
onto the guide bolts until the brake pad is also
1. Housing pressed against the brake disk.
2. Pressure ring The brake is released by complete pre-tensioning of
the bank of cup springs. During this process,
3. Thrust bolt through application of the necessary release
4. Adjusting screw pressure after overcoming the cup spring force, the
5. Bank of cup springs piston must move back until it comes to rest
6. Piston against the pressure ring.
7. Lining pad The clamping force diminishes with wear of the
8. Lining pad brake lining and brake disk. The brake must be
adjusted at the latest at the times indicated by the
9. Gliding bolt adjusting specification below.
62
Brake system components: Handbrake adjustment
Disassembly – Assembly:
1. Put machine on an even surface+secure against rolling away.
2. Release the screw cap.
3. Release the lock nut and turn the screw (3) anticlockwise
using a size 8 or 10 socket wrench until the pressure bolt
comes to rest against the even surface of the piston. In this
status, the brake can be mounted or demounted from the disc.
4. Mount the pressure connection again.
5. Apply the necessary release pressure to the brake until the
bank of cup springs is completely pre-tensioned.
Basic Setting.
1. Turn the adjusting screw manually clockwise until both brake
pads make contact with the brake disk. Then it is not longer
possible to turn the adjusting screw without force.
2. Turn the adjusting screw anticlockwise in order to set the
following rated clearances.
1. Thrust bolt
2. Bank of cup springs
3. Adjusting screw
4. Screw cap
5. Lock nut 3. Hold the adjusting screw in position with a hexagonal socket
6. Piston wrench and lock with lock nut.
P. Even surface 4. Mount the screw cap and tighten as far as possible manually.
S. Socket wrench 5. Mount the pressure connection.
63
Brake system components: Emergency release.
1. The vehicle has to be secured against moving.

2. Release the screw cap and unscrew (4).
3. Release the lock nut (size 24 or 30) and turn
the adjusting screw with socket wrench size 8 or
10 manually counter-clockwise until the brake
disc is free.
Caution!
For the emergency release is an actuation
torque of 40 Nm respectively 70
Nm required .
4. Mount the lock nut and the screw cap and

tighten both as far as possible manually.
1. Thrust bolt
2. Bank of cup springs Caution!
3. Adjusting screw Now, the vehicle do not have any brake
4. Screw cap function. The vehicle must be secured
5. Lock nut against moving with proper means.
6. Piston Before putting the vehicle into operation
P. Even surface again, the brake has to be adjusted again.
S. Socket wrench
64
Brake system components: Accumulator / switch.
Purpose:
- Fluids are practically incompressible and are thus incapable of
accumulating pressure energy. In hydro-pneumatic 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.
65
Brake system components: front axle brake discs.
1. Brake carrier
2. Brake housing
3. Piston
4. Inner disk
5. Outer disk
6. O-ring
7. Screw
8. Screw plug
9. Seal ring
10. Seal ring
11. Connection piece
12. Breather
13. Sealing ring
14. Sealing ring
15. Spring
16. Screw
17. Seal ring
18. Screw plug
19. O-ring
20. Face seal
21. Screw
22. Tube
23. Bushing
24. Screw
66
Brake system components: Operational checks.
67
Brake system components: Operational checks.
68
69
Steering system: layout.
MCV main pressure On T/M

Check point: PTO
210 /185Bar.
Priority 2 Sucking
valve lines from
oil tank
Steering
Pressure
Check point
175Bar.
70
Steering system: Hydraulic diagram.
Turn left Neutral Turn right
= Overload
pressure relief
valves set on
(225Bar)
to prevent the oil
from flowing into
main system
when the
steering cylinder
is pressurized by
external forces.
175 175
175
Bar Bar
Bar
71
Steering system: Steering unit.
72
Steering system: Operational checks .
STEERING UNIT LEAKAGE TEST:

- Oil temperature must be 45±5°C
- Engine @ speed High idle
- Maximum steering unit leakage 7.5ℓ/min
PROCEDURE:
- Check temperature.
- Disconnect return hose (T) from fitting.
- Install cap fitting on (T) hose.
- Run engine at high idle and rotate steering
wheel completely to the right (or left) with
approximately 1.2kgfm of force.
- Measure oil flow from return hose for 1 minute.
- If leakage is greater than 7.5ℓ/min. repair or
replace steering unit.
73
Steering system: Mechanical parts.
1. Steering axle assembly

1-1. Steering axle 1-26. Link
1-2. Knuckle 1-27. Link pin
1-3. Taper roller bearing 1-28. Bushing
1-4. Oil seal 1-29. Special washer
1-5. Retaining ring 1-30. Split pin
1-6. King pin 1-32. Hardened washer
1-7. Spacer 1-33. Hexagon bolt
1-8. Hexagon setscrew 1-34. Shim (0.2 t)
1-9. Hexagon nut 1-35. Boots
1-10. Cover 1-36. Hose clamp
1-11. Shim (0.1t) 1-37. Hose clamp
1-12. Shim (0.2 t) 1-38. Grease nipple
1-13. Shim (0.5 t) 1-39. Rear support
1-14. Hardened washer 1-40. Front support
1-15. Hexagon bolt 1-41. Bushing
1-16. Grease nipple 1-42. Spacer
1-17. Hub 1-43. Shim (0.2 t)
1-18. Oil seal 1-44. Shim (0.5 t)
1-19. Taper roller bearing 1-45. Connector
1-20. Special washer 1-46. Cover
1-21. Lock nut 1-47. Spacer
1-22. Split pin 1-48. Plate
1-23. Cap 2. Hardened washer
1-24. Bolt with washer 3. Hexagon bolt
1-25. Hub bolt 4. Hub nut
74
75
Hydraulic system: Overview (Main circuit).
1. Main pump
2. Auxiliary pump
3. Main control valve
7. Positioner valve
11. Remote control valve
13. Lift cylinder
14. Tilt cylinder
15. Positioner cylinder
16. Side shift cylinder
19. Pressure switch
23. Strainer
24. Return filter
25. Down control valve
30. Shockless valve
34. Hydraulic oil tank
76
Hydraulic system: Overview (Pilot circuit).
1. Auxiliary pump on engine PTO.

2. Safety valve (OPSS) (Solenoide).
6 3. Measuring point pilot pressure (30~40 bar).
4. Line filter.
5 5. Accumulator.
7 6. Brake Cut off valve (120~150 bar).
7. RCV Cut off valve (30~40 bar).
8 8. RCV Relieve valve (60 bar).
9. Line filter.
4 10. Fan drive motor (On rear cooler).
9 11. Fan EPPR valve (160 bar).
3 10 12. Orifice.
16 13. Hydrailic Oil Cooler.
2 14. Remote Control valve (RCV levers).
1 15. Hydraulic tank. (1000h oil change interval).
11 12 16. Check point Brake/pilot pressure (170 bar)
13
14 15
77
Hydraulic system: Overview (Pilot circuit).
5. Pilot system
accumulator 7. RCV cut off
valve 40~30Bar
6 9. Line filter
Brake system
5
16.Input
accumulator
pressure 170Bar
8 7
8. RCV relief valve
60Bar
4
9 6. Brake cut off valve
3 10 150-120Bar
3. Pilot pressure to 2 16
RCV30~40Bar
1
11 12
13
14 15
78
Hydraulic system: Remote control valve (RCV).
1. Inlet from hydraulic pump

2. Outlet to tank
3. Pilot passage
4. Closed passage(Not used)
5. Passage to head end of lift cylinders (lift up)
6. Return passage to tank
7. Lift spool
8. PV₁(Hydraulic pressure from joystick)
9. PV₂(Hydraulic pressure from joystick)
Return line
Pressure line 30-40Bar
Pressure to MCV spool
79
Hydraulic system: Main circuit.
1. Main pump on T/M PTO.

3. Main control valve (MCV).
4. Steering unit underneath steeringwheel.
7. Positioner valve in mast.
11.Remote control valve (RCV) in cabine.
12. Steering Cylinder.
13. Lift cylinders
14. Tilt cylinders.
15. Positioner cylinder.
16. Side shift cylinder.
23. Strainer.
24. Return filter.
32. Orifice before hydraulic oil cooler.
33. Oil cooler
34. Hydraulic oil tank
80
Hydraulic system: Main circuit.
Out
73cc/rev. During lift and tilt
summation: 73+61cc/rev
61cc/rev.
EF LS CF In
81
Hydraulic system: MCV function.
73cc/rev. P2 Main relief

Main relief P2
valve P1
61cc/rev
Side shift Right Side shift Left
Lift
summation
Tilt Positioner In Positioner Out

Summation
Lift
Tilt Forward Tilt Backwards
Tilt
Lift Down Lift Up
Positioner
Forward tilt Backward tilt
summation summation
Side shift
Summation Lift Lift up

Down summation
Main relieve pressure

settings: P1&2 :
Main relief
valve P2 110D/140D-7E: 185bar
73cc/rev
Main relief P1 61cc/rev. P1 130D/160D-7E: 210bar
82
Hydraulic system: MCV function.
Main relief P2 :
210/185 bar
Auxiliary relieve
valve: 165 bar
Auxiliary relieve:
165 bar
Main relieve valve

pressure P1&2 :
Main relief P1: 110D/140D-7E: 185bar
210/185 bar 130D/160D-7E: 210bar
83
Down control / down safety valve configuration.
V mast configuration TF mast configuration
84
85
Cooling system: System overview.
- Engine coolant cooler:

- 14,2L SAE10W-30 API Class
1 2 3 CH4.
-Front axle wet brake disks
cooler:
- 20L of hydraulic oil + 1L of
Lubrizol LZ9990A
-Transmission oil cooler:

- 16L SAE10W-30 / 15W-40
-Pumps on engine PTO.
-1 Front axle brake cooling.
-2 Brake system
pres.+RCV.
-3 Cooling fan on radiator.
- Hydraulic oil cooler:

- 115L ISO VG 32 / 46
- Turbo charger after cooler:

-To reduce NOx pollution.
- To improve engine efficiency.
- To remove some of the heat
from the (compressed) intake air
after the turbo charger. - Proportional controlled fan.
86
Cooling system: T/M and Front axle brake discs.
T/M cooling Brake discs

outlet. cooling inlet.
Front axle RH
brake discs
cooling outlet. Brake discs
cooling
outlet.
Front axle RH
brake discs
cooling inlet.
Triple pump
Front axle LH on engine
brake discs PTO (last T/M cooling
one)
cooling outlet. inlet.
Front axle LH
brake discs
cooling inlet.
87
Cooling system: CAC and engine coolant cooler.
Turbo charger
after cooler
outlet pipe.
Turbo charger
after cooler
inlet pipe.
Engine coolant
upper inlet.
Engine coolant
Lower outlet.
88
Cooling system: hydraulic oil cooler.
Hose from
auxiliary pump. Hose from
cooler outlet
to oil tank.
Hose to hydraulic
oil cooler inlet.
This hose is
combined with
return hose from
MCV and then the
oil goes to cooler
89
Cooling system: EPPR controller.
90
91
Electric system: Component location.
Master switch : ECM :

Behind battery set , Mounted on engine
under Step RH RH side
Battery relay CR
FDCU :
1: Fan Drive
In engine
Control Unit :CN59
compartment RH
CN54
side bolted on side Location: behind
plate
Relay board.
#2 Location after
modification: next to
RCV valve
92
RH Side door relay board:

Relays
Fuse box 1: Always power Relays

(Also with Battery RY OFF)
Relays
Relays
Fuse box 2: Power if
battery RY. is ON
Relays
Cluster / Monitor
plug
Fuse box 3: Power if T/M AEB test plug

battery RY. is ON
FDCU
ECU
93
RH Side console:
OPSS – unit : safety

device , seat switch: CN 55
Converter: 24 V-12V: CN
138
TCU : Transmission control

unit : CN 50
CN1 and CN2 connectors
94
Monitor:
-Camera
-ESL (engine start limit) :
password required if actieve.
Switches :
-Cruise control
-Inc/Dec
-Engine mode
Handsfree set:
Aircon / Heater
controler:
Cluster Menu :
1.RPM
2.Odo meter
3.Hourmeter
4.Cruise function
5.Model
6.Error code T/M control
display:
shows direction, gear
and error codes
95
Inching sensor check point :

CN19
Inching sensor :
CD 71: Next to LH inching pedal
96
Electric system: O.P.S.S. function.
- OPSS Function:
Safety system, to prevents travel and hydraulic functions in case the seat switch
is not activated (closed).
1.Controller In RH console box, collects informaton

2.Seat switch is activated if driver is on the seat
3.CR 50 : cuts out the travel
4.CR 52 : cuts out hydraulic, by switching off the relay, that powers the solenoid
CN 131
5.In case the gear selector is in neutral and the seat switch is not activated, the
parking brake will be engaged automatcially.
6.In case gear selector is in Forward or Reverse position and the seat switch is
disactivated (open), T/M will shift to Neutral. After reactivating the seat switch
(closing), gear selector must be reset to N before selecting F or R.
97
To gear selector
Seat
switch
CN3:
behind
seat
Cluster
98
+ from fuse box
-Function Attach cut off solenoids:
1.Key switch off: disactivated

2.Key switch on: activated
3.When seat switch is off (Open) :
attach cut off disactivated
Location of pilot valve
behind joystick (RCV)
valve. Underneath Connector CN 131
hydraulic levers.
99
Electric system: Switch configuration.
1. and 2.: Please find detailed explanation

about the cruise control function on next pages.
3. -First step: Clearance lamp and cluster lamp
ON.
1.
- 2nd step: Head light come ON.
2. 4. -First step: Front work lamps ON.
3.
4. - 2nd step: Rear work lamps ON.
5.
6.
5. The 4 flash lamps we be ON at the same
7. time .
8. 6.- First step: Rear wiper will operates.
9.
10.
2nd step: Liquid is sprayed + wiper (during
11. press)
12.
13. 7. Aircon ON / OFF
8. Heater in seat ON / OFF
9. Parking brake ON / OFF
10. - First step: Manual mode (gear selection).
2nd step: Automatic I: 1st to 3rd gear.
3rd step: Automatic II: 2nd and 3rd gear .
11. If pressed: Inching function activated +
lamp
12. Idle speed adjustment by 25rpm up or
down.
Idle RPM returns to normal value after restart.
13. – Standard mode: max. fuel efficiency.
- Power mode: Max. power output.
100
Electric system: Cruise control function.
Switch to engage cruise Switch to set Cruise

control : If selected, the control or To resume: in
message: “Cruise ready” will case cruise control has been
appear on cluster. cancelled by:
- Cruise control not possible if - Activating inching switch.
inching function is selected. - Operating the brake pedal.
In this case cruise control selected at 1572

RPM : - RPM will remain 1572 without touching Acc.
Pedal : message on cluster: “Cruise active”.
- RPM will increade if the accelator pedal is pressed,
but it will return to its preset value at pedal release.
101
Electric system: Cruise control function.
102
Electric system: Power mode: Standard / High.
Behind relay
board
103
Electric system: Idle increase / decrease switch.
104
Electric system: Monitor, Rear view camera, ESL.
105
Electric system: Monitor, Rear view camera, ESL.
Fuel injection system will be blocked if password is not

correct.
106
Electric system: Diagnostic tool connections.
ZF connector :
cluster Monitor 1.Connect AEB
2.Connect ZF Test man
To connect Insite :
you would need the
cable:3162848 to
connect from here to
insite software
adapter
Fuse box
3 ECU
107
Electric system: Accelerator pedal.
+5V
108
Electric system: Accelerator pedal.
5V
0V
Connector
CN93:
Between main
harness and Engine datalink
engine For Cummins
harness software
109
Electric system: Cluster.
Right turning pilot lamp
Transmission Temp. lamp
110
111
°C)
(107
112
Electric system: Cabin tilt system.
RH side
Next to
chassis
Next to T/M
113
Electric system: FDCU “Fan Drive Control Unit”
-Advantage of fan motor:
1) Adjustable fan speed independent of engine rpm

2) Reduce fan noise(112→107db) by decreasing fan
speed(2300→1600rpm)
- Logic of fan control:
Combination of Proportional
control1) of engine coolant
temperature and
On-off control2) of transmission
sump temperature(T) & intake
air temperature(I)
114
Before improvement of CN-59

After improvement of CN-59.
location : near RCV valve
Location Before
improvement : behind
the relay board.
115
116
Fan Motor
EPPR Valve CN:

154
- In order to check the mAmps, a special connector needs to

be fit between this connector and the EPPR valve, with two
extension wires, cut the wire 503 and connect and Amp meter
in series. Fan motor: location at the rear side.
EPPR valve – Relief Valve: location
Amp at the bottom of the fan motor
New meter
Connector Check m Amp: build special
CN154 connector and measure between wire
503
Pressure check point: at the top of
EPPR the fan motor
117
Locking nut.
Adjust pressure over here.
118
119
Engine assy.: Specifications.
- Manufacture: Cummins.
- Power: 119KW (162hp) @ 2200rpm.
- Torque: 731,6NM @ 1400rpm.
- Emission: EU-Stage IIIA.
- Fuel consumption: - 110/130 = 11l/h,
- 140/160 = 11.5l/h.
- High pressure common rail fuel system (BOSCH)
- Full Authority Electronic control.
- 1600Bar Injection pressure capability.
- Pressure independent from speed
- ECM version CM850.
120
Engine assy.: Layout.
121
Engine assy.: High Pressure Common Rail.
122
Engine assy. components: Fuel filter.
1. Filter efficiency : 98% @ 10㎛ dust
2. Fuel Heater specs: Hand

pump
- Voltage: 24±4V.
- Power: 200±50W.
- Current: 15A.
Fuel heater Heater
Connection CN96
3. Fuel Heater operation:
- Fuel warmer automatically activates Fuel filter
according to fuel temperature.
- 15A initially flows for 1~2 min. to
prepare for starting.
- When fuel starts flowing, ceramic in heater
senses the fuel temperature and lower the
current up to 1.5A to avoid fuel overheating.
4. Activation specs:
- Coolant temp.- Below 10ºC. Water
separator
5. Deactivation specs:
- Coolant temp.- over 60ºC. Water sensor
- After 30 min. of operation. CD-35 (WIF)
123
Engine assy: Fuel system air bleeding procedures
124
Engine assy.: Sensor location.
1.WIF Sensor CD-35:
2. Crankshaft speed and camshaft position Hall effect sensor.
<27
<48
<16
<26
<47
<37
125
3. Rail Fuel pressure sensor.

<47
<25
<37
4.Intake manifold pressure / air temperature sensor.

<44
<37
<23
<47
126
5. Engine oil pressure sensor.
<13
<33
<38
6. Barometric (Ambient) pressure sensor.

<03
<38
<33
127
7. Engine coolant temperature sensor .

<15
<38
8. Engine oil pressure switch.

<17
Pressure switch opens at (0.55 bar)
128
Engine assy.: ECM : CM850.
DE
E SS SI
HARN
60 PIN
50 PIN
HAR HAR
N ESS N
SIDE ESS
SIDE
129
Engine assy.: Engine harness.
130
Engine assy.: How to readout engine error codes.
131
Engine assy.: How to readout engine error codes.
-A complete error code list + failure definitions can be

found in the additional map, that you will receive during
training.
- All Cummins software and engine check tools can be
purchased through the Cummins website:
http://powerstore.cummins.com/default.cfm?fuse=matri
x&browse_by=productType&brand=all&product_type=El
ecTool&product_category=all
132
Engine assy.: Maintenance recommendations.
-Initial engine oil + filter replacement after 50H.
- Next: each 500H, replacement engine oil + filter (14,2L SAE10W-30, API class: CH4)!!!
133
134
Mast section.
1. Outer mast 5. Lift chain 9. Chain bearing 1. Outer mast 5. Tilt cylinder pin 9. Sheave
2. Roller bearing 6. Anchor bolt 10. Anchor bolt 2. Shim 6. Mast pin 10. Anchor bolt
3. Tilt cylinder pin 7. Side roller 11. Roller bearing 3. Roller bearing 7. Inner mast 11. Chain
4. Mast mounting pin 8. Inner mast 4. Side roller bearing 8. Middle mast 12. Sheave bracket
135
Mast section.
1. MAST LOAD ROLLER ADJUSTMENT: 1. CARRIAGE LOAD ROLLER
- Measure the clearance with the mast overlap - Measure the clearance when the center of
at near 480mm. the carriage upper roller is 100mm from
- Shift the inner mast to one side to bring the the top of the inner mast.
roller into contact with the outer mast, and - Measure the clearance at upper, middle and
adjust the clearance between the roller side lower rollers after loosen the adjust screws
face and mast at the closest position on the from the side rollers. Shift the carriage to
opposite side to the following value by one side to bring the roller into contact
adjust bolt. with the inner mast, and measure the
- Standard clearance A, B = 0~0.6mm. clearance between the roller side face and
2. INNER/OUTER MAST ROLLER mast at the closest position on the
CLEARANCE ADJUSTMENT: opposite side to the following value by
adjust screw.
- Distribute the roller clearance equally to the - Standard clearance C = 0~0.6mm
left and right roller. - Distribute the roller clearance equally to the
- After the adjustment, check that the inner left and right roller. After the adjustment,
mast moves smoothly in the outer mast. the carriage should move smoothly along
136
the overall mast length.
137
Maintenance recommendations.
Operator manual Operator manual

page. page.
138
Maintenance recommendations.
Operator manual
page.
Operator manual
page.
139
Maintenance recommendations: lubrication chart.
1. SAE numbers given to engine oil should be selected according to ambient temperature.
2. For engine oil used in engine oil pan, use SAE 10W oil when the temperature at the time of
engine start up is below 0。C , even if the ambient temperature in daytime is expected to rise
to 10。C or more.
3. 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.
140
141
Air Conditioning System: Contents.
Contents
Ⅰ. Air Conditioning System, Specification
Ⅱ. Air Conditioning System, Part List
Ⅲ. Air Conditioning System, Components Description
Ⅳ. Air Conditioning System, Control System
Ⅴ. Air Conditioner, Notice
Ⅵ. Refrigerant Charging
Ⅶ. Checking and Maintenance
Ⅷ. Air Conditioner, Troubleshooting
142
I. Air Conditioning System: Specifications.
Section
Section Item
Item Specifications
Specifications Remarks
Remarks
Core
Core Type
Type Multi
Multi Flow
Flow
Capacity
Capacity 5,000
5,000 kcal/h±
kcal/h±±10%
± 10%
Eva.
Eva. Unit
Unit Blower
Blower Air
Air Flow
Flow 500 /h±
500 ㎥/h±
㎥ 10%
±10%
±
Exp.
Exp. Valve
Valve 1.5
1.5 RT
RT
Cooler
Cooler Type Wobble
Type Wobble Plate
Plate Variable
Variable Displacement
Displacement
Part
Part Compressor
Compressor Displacement
Displacement 151
151 cc/rev
cc/rev
Core
Core Type
Type P.F.
P.F.
Cond.
Cond. Unit
Unit Capacity
Capacity 8,000
8,000 kcal/h (min)
kcal/h (min)
R/Drier
R/Drier Capacity
Capacity 210
210 cc
cc Combined
Combined with Cond..
with Cond
Core
Core Type
Type Parallel
Parallel Flow
Flow
Heater Htr.
Htr. Unit
Unit Capacity
Capacity 7,000
7,000 kcal/h±
kcal/h± ±10%
10%
Heater
±
Part
Part Blower
Blower Air
Air Flow
Flow 500 /h±
500 ㎥/h±
㎥ ± 10%
±10%
Water
Water V/V
V/V Type
Type Solenoid
Solenoid Valve
Valve Open/Close
Open/Close
Air
Air Flow
Flow Control
Control 44 Step
Step
Controller
Controller Mode Control
Mode Control 5 Mode
5 Mode
Temp.
Temp. Control
Control 2
2 Step
Step Warm/Cool
Warm/Cool
Refrigerant
Refrigerant HFC-134a
HFC-134a
Electrical
Electrical Consumption
Consumption DC
DC 24V
24V
143
II. Air Conditioning System: Parts list.
4
4 PART
PART LIST
LIST
1
1
No.
No. PART
PART NAME
NAME
0
0 AIR
AIR CON
CON &
& HEATER
HEATER ASSY
ASSY
EVA. CORE 1
1 AIR
AIR CON
CON &
& HEATER
HEATER UNIT
UNIT
EVA. CORE 2 COMPRESSOR
2 COMPRESSOR
OUTLET PIPE
3
3 CONDENSER
CONDENSER ASS’Y
ASS’Y
4
4 CONTROLLER
CONTROLLER
2
2 TXV EVA. CORE 5 PULLEY-TENSION
7 5 PULLEY-TENSION
7 INLET PIPE
6
6 V-BELT
V-BELT
7
7 HOSE-SUCTION
HOSE-SUCTION
9
9 8
8 HOSE-DISCHARGE
HOSE-DISCHARGE
9
9 HOSE-LIQUID
HOSE-LIQUID
8
8
EVA’ CORE
3
3
5
5 6
6
TXV
COMP’
COND’
144
Air Conditioning System: Parts list.
1-1
1-1 2
2 PART
PART LIST
LIST
No. PART
No. PART NAME
NAME
0 HEATER
0 HEATER ASSY
ASSY
HTR. CORE 1
1 11 HEATER
HEATER UNIT
UNIT
INLET PIPE
1-1 HEATER
1-1 HEATER CORE
CORE
1-2 WATER
HTR. CORE
1-2 WATER VALVE
VALVE
1-3
1-3 HOSE
HOSE -- INLET
INLET
HTR. CORE
OUTLET PIPE 1-4 HOSE
1-4 HOSE -OUTLET
-OUTLET
1-5
1-5 CLAMP
CLAMP -- HOSE
HOSE
1-2
1-2
1-6
1-6 HEATER
HEATER INLET
INLET PIPE
PIPE
2
2 CONTROLLER
CONTROLLER
1-3
1-3 1-6
1-6
OUT
1-4
1-4
IN
HTR CORE OUT

ENGINE
1-5
1-5 E/G INLET
HTR CORE IN E/G OUTLET
145
III. Air Conditioning System: Components.
-Air Conditioning System: Cooling system +

Heating System (HVAC):
- Major component: HVAC UNIT (Heating Ventilation

Air Conditioning) , CONDENSER, COMPRESSOR,
CONTROL UNIT, Pipes.
① Location: Base plate of cabin, underneath seat

② Major part: EVA. & H/T, BLOWER UNIT.
③ Function: Refrigerate/Heat the intake air
(A/C and H/T) and deliver to the cabin Inside.
146
Air Conditioning System: Accessing HVAC unit
-Accesing the HVAC unit:
- Remove bolts (move

seat back and forth) to
remove the seat
- In case of a heated
seat is present: first
disconnect wires.
1. Remove the mat from cabin 2. Remove seat
3. Remove upper cover 4. Remove lower cover

147
Air Conditioning System: Accessing HVAC unit
5. Remove book box at rear side 6. Remove seat base
7. When you remove seat base, you see the unit

148
Air Conditioning System: Components.
A
- EVA and HTR core:
A. Evaporator core lowers the temperature through phase

change (refrigerant gas) during liquefied refrigerant flow
and this results in cooling function by heat exchange with air.
- In case of temperature drop below freezing point with core,
thermocon. (safety device) automatically inactivates the
compressor clutch to prevent core from freeze
B
B. Heater core allows heated coolant(80~85℃) into core for
heat exchange with air.
149
- Expansion valve on EVA core:
- Connection: inlet/outlet pipe at evaporator core.

- Function:
- Changes liquefied refrigerant (high temp./pressure) to
x vaporized refrigerant (low temp./pressure) by means
vvvof decompression/expansion.
- Controls the flow of refrigerant to maintain superheat
xxx for evaporating refrigerant at evaporator outlet.
- Controls the inlet flow of refrigerant by sensing the
cccctemp. of refrigerant at extension valve outlet for total
ccc refrigerant flows.
- If temp. of outlet refrigerant increases, quantity of
ccccrefrigerant flow becomes less due to upper movement
xxx of diaphragm, shaft, ball valve that reduces the flow
ccccspace.
150
-Thermocon:
Location: Evaporator outlet

Function:
- Inactivates compressor clutch at 1.0±0.5℃. Because it
ddxcan be overloaded by icing when temp. of evaporator
xxxoutlet reaches freezing point.
- When the temperature goes up and temp. difference is
xxx1.3℃, clutch active, compressor works.
- Motor and blower
Composition: Motor, blower.

Function: Taking air into heat exchanger.
151
- Resistor:
- Control amount of air flow by adjusting voltage of blower

motor.
- Amount of air flow(4 steps) is controlled by resistor
connected to control switch.
4 step: DC 24V(battery voltage) to motor.
1,2,3 step: Lower voltage than battery voltage to motor.
- Fuse is applied to protect system from over current and set
to be xblockout at 217±10℃.
OUTLET
(HTR CORE INLET) - Water Valve:
-Device to block/supply heated coolant to heater core.

Heater on: valve open
Cooler on: valve close
INTLET
(E/G OUTLET) When assembling valve and rubber hose, clamp must be firmly
tightened to avoid any coolant leakage.
152
- Actuator:
- Motor to control door (blower ports) for mode selection.

- Door (Port) is activated to designated position when
actuator is powered and signal set by control logic.
- Actuator driver:
- Control circuit of actuator to control position of door.

- Door is controlled by signals from the mode selection at
ccontrol switch.
153
- Compressor
- Driven by: engine belt compressor clutch compressor.

- Refrigerant (vaporized low temp./pressure) through
evaporator erefrigerant (vaporized high temp./pressure)
through compressor.
154
-Variable operation - Maximum condition
Discharge Discharge
Supplied room
room
Control room Control room
oil flow
Pressure increase Pressure decrease
Discharged oil flow Discharged oil flow
Diaphragm
Control Control
valve open (sensing Ps) valve close
position position
• Decreased pressure than Suction port setting (1.9 bar) • Increased pressure than suction port setting (1.9 bar)
• Diaphragm contracted Open control valve • Diaphragm expended Close control valve
• Supply discharged refrigerant into control room pressure decrease in control room
pressure increase in control room • Angle of swash plate is increased increase discharge
• Angle of swash plate is reduced discharge capacity capacity
reduced
155
- Condenser:
- In the condenser heat is extracted from the

Inlet Port compressed refrigerant coming from the compressor.
(HOSE-
(HOSE-DIS.)
Outlet Port -In case of malfunction of condenser cooling, system
(HOSE-
(HOSE-LIQUID) xbecomes overloaded and less efficient.
- Possible cause: dust on condenser fins, not sufficient
air supply for cooling from fan shroud.
Regular condenser cleaning is required.
- Receiver Drier:
Receiver Drier Function:

- Delivering only liquefied refrigerant to expansion valve
after separating the mixed refrigerant (liquid and gas)
from condenser as well as separation of water/foreign
particles.
156
IN Receiver Drier
Refrigerant Flow:
H/pipe Cardridge
CONDENSER
Filter
IN
OUT
OUT
Filter Cardridge
157
- DPS (Dual Pressure Switch)
- Safety device for Air Conditioning System.

- Location: Receiver drier (high pressure side)
- Difference of refrigerant pressure
Operation pres. for pres. switch over 32±2kgf/ cm² Compressor clutch (Inactive)
6±2kgf/ cm² Compressor clutch (Active)
2±0.2kgf/ cm² (Insufficient amount of refrigerant)
Compressor clutch (Inactive)
0.25kgf/ cm² Compressor clutch (Active)
Liquid Hose
158
- Air flow distributor:
- Air from HVAC unit is distributed to DEF,

FACE, REAR by doors according to each
mode.
- Position of door is controlled by actuator
that is set be control switch and control
logic.
159
Discharge Hose
- Refrigerant hoses:
-Material of hose inside (Polyamide),

outside (EPDM / ethylene propylene
diene Monomer): it can minimize the
leakage of refrigerant.
Suction Hose -Hose end has flanges for connection
and o-ring to avoid any leakage.
(There is no o-ring for hose flange at
compressor side. Because o-ring is
Liquid Hose applied on compressor inlet/outlet )
160
IV. Air Conditioning System: Control system.
Blower Switch Mode Switch A/C& H/T Switch

Function Symbol Description Function Symbol Description Function Symbol Description
Blower FRONT Air-

(BLUE)
Stop FRONT 100% Conditioner
A/C ON
1 STEP FRONT 70% &
Blower Air (H/T OFF)
REAR 30% H/T
Speed Flow REAR
2 STEP (RED) Heater
REAR 100% Selection
ON
Selection Selection (A/C OFF)
3 STEP FRONT 70%
DEF 30%
DEF
4 STEP
DEF 100%
161
Air Conditioning System: Electric diagram.
162
V. Air Conditioning System: Important notice.
- Aircondioning oil:
When you replace some parts related to the airco system, or check the refrigerant level,
please check/add arico oil
Description Amount Description Amount

Refrigerant re-charging + 30cc Hose, pipe replacement +30cc
EVAP. Replacement +50~60cc R/Drier replacement +30cc
Cond. Replacement +50~60cc Compressor replacement -120cc
Compressor ass’y 240cc
When you replace the compressor you need to check the oil New Old
Compressor Compressor
quantity in the compressor.
- The compressor has 240cc oil inside, this is delivered to the other
parts during air-co operation. When faulty compressor is replaced,
faulty old compressor has 120cc left inside.
- You need to match up the proper oil level in the system by
removing some oil from new comp. If this is not done, the quantity
of oil will increased when you replace new compressor without any
adjustment.
-(Initial 240cc - faulty comp. 120cc + new comp. 240cc = 360cc)
This will affect cooling performance.
163
VI. Air Conditioning System: Refrig. Charging.
- Quantity of refrigerant applied in 110 160D-7E is +/- 900gr.
Filling point
Filling point
Discharge Hose
Suction Hose
164
VII. Air Conditioning System: Maintenance.
Intervals
Component Check item 6-months 12-months
Refrigerant Volume ● ●
Condenser Fin Clogging ● ●
Idle Pulley Operation ●
Belt Damage & Tension ●
Control Operation ●
Pipe laying, Mounting State,

Leak of Connection, ● ●
Connecting points
Parts, Damage
Compressor Operating Condition ●
165
Air Conditioning System: Maintenance.
Group Items Check point
1. Check operation
Compressor
2. Check amount of lubrication oil and add
Condenser 1. Check and clean
Evaporator 1. Check
High/Low pressure switch 1. Check
Refrigerant
Receiver drier 1. Clean or replace
1. Check service valves
2. Check bolt/nut for each unit or hose connections.
Etc.
3. Check for leakage of refrigerant in unit or hose connections.
4. Check drain hoes for its clogging and clean
1. Check compressor pulley and v-belt.
Engine Power train
2. Check alignment of v-belt and pulley.
1. Check each button

2. Check each lamp
Control switch
3. Check harness terminals and disconnections.
4. Check for any breakage.
Articulated joint 1. Check for any abnormal harness connection.
Condenser fan 2. Check ground(-) connection with frame
Electric
3. Check terminal connection
Evaporator blower
4. Check harness damage
Electric clutch 5. Check any motor restriction.
1. Check fuse
Other electric/electronic part 2. Check relay
3. Check harness and terminal/ disconnection
166
Air Conditioning System: Checks.
Procedure
1. Check whether V-BELT is loosened or damaged.

Check alignment of crack pulley and compressor pulley.
2. Check compressor is contaminated by dust or oil and clean with
Before
air, if necessary.
operation
3. Check bolt/nut for tightening.
4. Check for any refrigerant leakage at unit, hoses, connectors and
tighten, if necessary.
1. Check for ventilation after power switch “on”.

2. A/C S/W “ON” and check cooling system is properly working
Operation according to setting value.
3. Check air flow and coldness of air from duct.
4. Check high/low pressure switch
Stop 1. Check whether cooling system stops after “OFF” button.
167
VIII. Air Conditioning System: Troubleshooting
- Troubleshooting without diagnostic tool:
① Abnormal noise at V-belt:

: Check the tension of V-BELT and alignment.
② Abnormal noise at compressor area:

: Check for any un-tightened bolt/nut for compressor and bracket.
③ Abnormal noise at compressor:

: Check for any damage in compressor inner parts (bearings.)
④ Contamination around condenser by dust or particles:

: Clean the dust or others from condenser to minimize the loss of cooling efficiency.
Be careful not to damage core fins while cleaning.
⑤ Abnormal noise at fan motor: Check fan motor and repair or replace.
If there is any interference around fan, remove the cause.
168
Air Conditioning System: Troubleshooting
- Air temperature: 30~35℃ ℃ , ENGINE rpm: 2,400
Normal
System
High : 15~18 kgf/cm² G (1.47~1.76MPa)
Low : 1.0~2.0 kgf/cm² G (0.098~0.196 Mpa)
Case ① : Pressure (High) is higher than specification.
No Possible cause Remedy

Air/Non-condensable Re-collect all the refrigerant to make
1 gas is inside of line to be completely vacant and put
refrigerant line. in back to line.
2 Overcharge of refrigerant Take out surplus refrigerant

Clogging at condenser Clean the condenser with air or
3 water.
or contamination.
Failure with condenser Check and repair or replace, it

4 fan or its breakage. necessary.
169
Case ② : Pressure (High) is lower than specification.

Liquefied refrigerant is involved
1 Check “A” in expansion valve.
in intake gas.
2 Failure with expansion valve Replace

A
Breakage of outlet valve in
3 compressor
Replace compressor.
Strainer in compressor intake is

4 clogged.
Check and clean.
Case ③ : Pressure (Low) is higher than specification.
Too much supply for Check whether “A” is located

1 liquefied refrigerant at against inlet and replace it, if
expansion valve. necessary.
2 Failure with expansion valve Replace the valve.
Leakage at compressor
3 Repair the compressor.
inlet/outlet vale.
170
Case ④ : Pressure (Low) is lower than specification.

There is clogging at drier, Replace drier or check
1 expansion valve.
expansion valve and etc.
2 Insufficient refrigerant Replenish the refrigerant.
Icing on evaporator and loss of

3 Stop the operation for a while.
its capacity.
Air intake/filter/evaporator core
4 Check and clean.
is contaminated.
Expansion valve pipe damage or Replace expansion valve and

5 breakage. pipe line.
Re-collect the refrigerant in

line and make the line to be
6 There is ice in expansion valve. vacant. Then remove the
water and replenish the
refrigerant.
7 Failure with expansion valve. Replace it.
Improper harness connection for Check and replace, it

8
blower. necessary.
171
Problem Possible cause Action taken

Inactive with 1. Main fuse for cooler has melted 1. Replace fuse
S/W ON 2. Power harness is disconnected. 2. Check harness
1. Abnormality of refrigerant 1. Check refrigerant

(abnormal high/low pressure)
Warning lamp is
2. Malfunction of pressure switch 2. Replace pressure switch
unceasingly on
3. RELAY failure 3. Replace RELAY
4. Abnormality of harness 4. Check harness
1. Failure with blower (Motor, harness) 1. Check harness or replace motor.

Air flow is not
2. Failure with relay/fuse for blower 2. Replace relay or fuse.
sufficient
3. Icing on evaporator core 3. Stop the operation for a while.
1. Improper temperature setting 1. Re-set cooling temperature

No cooling 2. Failure with compressor clutch 2. Check compressor clutch
3. Harness disconnection 3. Check harness
1. Failure with condenser fan 1. Check harness

Not sufficient
2. Failure with temperature sensor 2. Replace motor
cooling 3. Replace temperature sensor
Fuse is cut 1. Related power line is short. 1. Check harness

with key on 2. Motor is restricted. 2. Remove the cause of restriction
1. Check Sol valve at engine room side. 1. Check valve

Heated air is
2. Check harness for SOL valve. 2. Replace valve
coming
3. Manually close the water valve
172
Defect Possible Cause Location Remedy
Water valve 1. Check water valve

2. Replace water valve
Blower is running
1. Water valve 3. Check actuator
but no difference
2. Water valve wiring driver
of temperature
3. Replace actuator
Actuator driver
driver
1. Check buttons/dials
No reaction after
1. Control switch 2. Check terminals of
switch selection
the wiring
1. Clamp at 5mm to
1. Heater hose clamp the end of hose.
Water leakage
2. Heater hose connection 2. Connect hoses to
water valve tightly.
Inlet hose Outlet hose
173
Defect Possible Cause Location Remedy
Blower
motor
1. Blower
1. Check wiring
No Air blow (Motor/broken
& Replace motor
wires)
Fuse melts Fuse

1. Check wiring
1. Short from the
when resistor 2. Remove the cause
power.
is switched of the restriction to
2. Motor is restricted
ON the motor
174

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We build a better future

A. Machine specifications and features Page: 2-9

Cummins (High pressure

Rated gross horse power 162PS( 119Kw)

Model Unit 110D-7E 130D-7E 140D-7E 160D-7E

Load center mm 600 600 600 600

Lifting height (Stand.) mm 3,305 3,305 3,305 3,305

Min height mm 3,150 3,150 3,400 3,400

Travel speed(Unload) km/hr 35.0 34.8 33.8 33.6

Gradeability(Load) % 39.2(1mph) 33.2(1mph) 30.0 (1mph) 27.5(1mph)

Traction (Load) kg 9,267(1mph) 9327 (1mph) 9325 (1mph) 9359(1mph)

Model Unit 110D-7E 130D-7E 140D-7E 160D-7E

Tipping Load kg 16,619 18,974 20,988 22,982

WHEEL BASE mm 2,900 2,900 3,300 3,300

Front mm 1,842 1,842 1,842 1,842

Cummins Cummins Cummins Cummins

Tire Front/Rear 10.00-20-16 10.00-20-16 12.00-20-18 12.00-20-18

1) ESL (Engine Start Limit) ○

Right turning pilot lamp

Detailed disassembly > assembly procedures and complete error

19 = Cable to filter contamination switch

NFS: Follow-on slide

1. Pressure reducing valve(9bar)

Main Pres.: 16Bar

K2: 16Bar Not Applied

KV: 16Bar KR:16Bar

K3: 16Bar K1:16Bar

= 1st speed forward

What: - It is the abbreviation for Automatische Ermittlung der Befüllparameter in German:

Procedure: (Recommended to execute after every 1000h of application).

1. Start engine after parking the machine on flat floor and

A detailed list of all possible transmission error

300. Planetary housing

- The axial clearance between axle shaft respective

1. Brake carrier 12. Breather

Brake system cooling outlet

Pressure to brake discs

Brake system cooling inlet

Adjustment of wheel bearings:

412. Bearing bushing

Front axle oil fill plug

Final drive Final drive filling position

After draining brake system

4. Accumulator from brake system.

5. P/SW TCU > rear brake lamps (5Bar +/-1).

6. P/SW charging (PS) (95bar +/-5).

7. Line filter on “PP” of cut off valve.

21. Pressure check port (0 > 105Bar)

64. Line filter on pressure line “P”

69. Brake valve inside cabin.

70. Brake pump on Engine PTO.

71. To hand brake cylinder on external disc.

* Pressure to RCV : 30 – 40Bar

Full braking position:

Limiting the braking pressure: (105Bar).

The two identical brake pads can slide freely on the

1. The vehicle has to be secured against moving.

4. Mount the lock nut and the screw cap and

MCV main pressure On T/M

Turn left Neutral Turn right