SERVICE GUIDE

HDF(HLF)20/25/30Ⅱ

After Sales & Service Department

2004. 11. 14
I. LAYOUT
1 : Mast
2 : Lift chain
3 : Lift cylinder
4 : Back rest
5 : Tilt cylinder
6 : Lift bracket
7 : forks
8 : Overhead guard
9 : Turn signal lamp
10: Head lamp
11: Operator seat
12: Bonnet
13: Counter weight
14: Rear wheel
15: Front wheel
16: Rear combination lamp
II. ENGINE
Compact and Powerful Engines

HDF20/25/30II

HLF20/25/30II
4G63 39ps/2300rpm
For HLF15/18II
 Model HDF20/25/30II HLF20/25/30II
Maker ISUZU MITSUBISHI
Engine Model 4JG2PJ-06 4G63-31HL
Type Water-cooled, 4Cycle diesel Water-cooled, 4Cycle LPG
Combustion chamber type Semi-spherical Semi-spherical
No. of cylinders and arrangement 4, In-line 4, In-line
Compression ratio 20.5 8.6
Bore x Stroke mm[in] 495.4x107[3.75x4.21] 86.5X100[3.41X3.94]
Total piston dispalcement cc[cuin] 3,059[187] 2,350[143]
Dry weight Kg[lbf] 244[538] 152[335]
Firing order 1-3-4-2 1-3-4-2
Fuel iniection timing (B.T.D.C) 6 9
Iniection pump Bosch VE type -
Governor Mechanical type Air fiow type
Low idle speed rpm 675 - 725 720 - 760
Iniection nozzle Throttle type -
Iniection starting pressure Mpa[Kg/㎠/psi] 14.7[150/2,130] -
Fuel filter type Cartridge paper element -
Valve clearance intake mm[in] 0.40[0.016]
exhaust mm[in] 0.40[0.016]
Oil capacity lit[US/gal.] 7.5[1.98] 4.0[1.06]
Cooling water capacity lit[US/gal.] 4.5[1.19] 3.1[0.82]
Lubrication oil API CC or CD API SD or SE
Water pump Belt driven impeller type Belt driven impeller type
Timing drive system Gear drive Gear drive
Number of piston ring Compression ring 2, Oil ring 1 Compression ring 2, Oil ring 1
Valve mechanism Over head valve Over head valve
Thermostat Wax pellet type Wax pellet type
Electrnator system 12V DC, Negative ground 12V DC, Negative ground
Alternator V-A 12 - 35 12 - 50
Starter motor V-Kw 12 - 2.2 12- 1.2
Outer components (HDF20/25/30II)
18 3 5 7 10 12

15
16
17

20 19 4 2 1 6 8 9 11 13 14
1. Cooling fan drive pulley 8. Injection pump 15. Fuel injection pipe with clip

2. Cooling fan drive belt 9. Oil pipe 16. Fuel pipe(in)

3. Water pump 10. Intake manifoid 17. Fuel pipe(out)

4. Alternator 11. Fuel cut solenoid 18. Exhaust manifoid

5. Thermostat 12. Breather hoes 19. Engine oil pressure sensor

6. P.T.O (Hyd’ pump) 13. Dipstick and guide tube 20. Oil filter

7. Fuel hose (Leak off) 14. Starter motor

Cooling system (HDF20/25/30II)

① 1. Coolant temperature sensor for monitor gauge

2. Coolant temperature for preheat
②
3. Thermostat : Wax pellet with jiggle valve
④ Initial opening temp [℃(℉)] : 76.5(170)
Full opening temp [℃(℉)] : 90 (194)
Valve lift at fully open position mm(in): 8(0.31)
4. Reservoir tank
⑤ 5. Water pump : Centrifugal impeller (100Lit/min)
bearing type : Double row shaft
Cooling system (HLF20/25/30II)
2

1. Coolant temperature sensor for monitor gauge

2. Thermostat : Wax pellet with jiggle valve
Initial opening temp [℃(℉)] : 80 (172)
Full opening temp [℃(℉)] : 90 (194)
Valve lift at fully open position mm(in): 8(0.31)
3. Reservoir tank
4. Water pump : Centrifugal impeller (100Lit/min)
Fuel system (HDF20/25/30II)
1

Fuel Injection Pump Fuel Tank

- Manufacturer : Zexel - Capacity : 47 liter
- #1 : Shut off solenoid - Drain plug on tank bottom
- #2 : Adjusting bolt for starting injection volume
Fuel system (HLF20/25/30II)
2
1
9

3
4
8
7

IMPCO LPG system

1 : Carburetor 6 : Fuel lock valve

2 : Air governor 7 : Vaporizer
3 : Idle adjust screw 8 : Engine shut off solenoid
4 : Throttle adjusting screw 9 : Acceleration link
5 : High speed adjusting screw
Air Intake system

2
3

4
1

1 : Clogging sensor for air filter

2 : Inlet hose
3 : Outlet hose to carburetor
5
4 : Air intake inlet
5 : Single filter, 13 μ
Double filters available as option
Lubrication system

6
5

4
1
HDF 20/25/30II
HLF 20/25/30II
2
1 : Oil filter
2 : Oil pressure switch Oil sump : 4.0 liter
HLF 20/25/30II 3 : Oil level gauge

HDF 202530II
4 : Oil filter
5 : Ventilation valve Oil sump : 7.5 liter
6 : Filler cap
Starting system, HLF Engine
2
4

1 3

1 : Ignition coil
Primary coil : 1.08 – 1.31 ㏀
Secondary coil : 22.1 – 29.9 ㏀
2 : Distributor
Pick up coil : 0.42 – 0.54 ㏀ 5
3 : Start motor
4 : Spark plug – 3000 hour replacement interval
5 : Start relay
Fuel System, HLF

2-1 : Coupling

2-2 : Coupling

2-6 : Relief valve

2-9 : Fuel lock filter

2-10: Vaporizer

2-16: Solenoid valve

6,7,8 : Water hose

9 : Water pipe
 Mixture
Vaporizer

2-1 : Coupling 10~12 BAR

2-2 : Coupling
Safety system
2-6 : Relief valve
40 BAR
2-9 : Fuel lock filter Lock & filter
Vacuum line
2-10: Vaporizer
Water hose
2-16: Solenoid valve

6,7,8 : Water hose

9 : Water pipe
 Fuel System, HLF

Fuel Shut
off valve
• Low Pressure Regulator

• The LPR is a combination vaporizer, pressure regulating device

• The LPR is a negative pressure two stage regulator that is normally closed
when the engine is not running
• Fuel enters the primary port and enters the heat exchanger where the fuel
expands
• As the fuel expands the pressure rises and control the pressure to 10.34 kpa
(1.5 psi)
• During crank and run conditions sufficient vacuum will be introduced into
the secondary chamber from the mixer drawing the secondary diaphragm
down allowing the fuel to flow into the mixer
• Increased vacuum in the secondary chamber increases the downward action
on the secondary lever causing it to open wider allowing more fuel to flow to
the mixer.
Fuel System, HLF
The following is the method of adjustment of the
Engine Adjustment carburetor and air governor on a
reassembled engine.
1. Ignition timing check procedure
1) Warm up the engine coolant temperature
80 to 95℃.(126℉~203℉)
2) Install the clamp of timing light to No.1
wiring of spark plug as figured.
3) Connect the red clip to "+" terminal of
battery and the black clip to the ground.
4) Start the engine and run it with idling rpm
(740 rpm).
5) Check the timing with timing light.

Spec : 9˚BTDC / 740 RPM

1

2. Ignition timing adjustment : In case that the checked

timing is less or more than the specification,
1) Loosen the mounting bolt(1).
2) To adjust the timing, turn the distributor to clockwise or
counterclockwise slowly.

Clockwise turn : Decrease

Counterclockwise : Increase
Fuel System, HLF
Idle speed adjustment

1) Let engine warm up until the engine coolant

temperature rises to 80 to 95℃(176℉~203℉).
2) Check the idle speed.
Standard value : 740±20 RPM
3) If idle speed does not conform to the standard
2 value, adjust it turning the throttle adjusting
screw ( 1 ).

Mixture adjustment

1) CO concentration
Standard value : 1.0%
2) If CO concentration does not conform to the
standard value, adjust the idle adjusting screw (2).

* If the CO concentration is lean, turn the idle

adjusting screw counterclockwise.
1 * If it is rich, turn the screw clockwise.
Fuel System, HLF Air governor adjustment

1) Place all the hydraulic levers in the neutral

position.
2) Depress the accelerator pedal all the way (The
carburetor throttle valve will open fully).
3) While holding the adjusting screw(2) to prevent it
from turning, rotate the adjusting nut(1) either
clockwise or counterclockwise to make the engine
1 run at 2850 rpm.

Adjusting nut (1) :

Clockwise turn : Increase engine speed.
Counterclockwise turn : Decrease engine speed.

Anti-hunting adjustment

1) Place all the hydraulic levers or power train in the

neutral position.
2) Depress the accelerator pedal all the way (The
carburetor throttle valve will open fully).
3) Slowly rotate the adjusting screw clockwise until
2 hunting disappears.

Adjusting nut (2) :

Clockwise turn : Increase spring tension.
Counterclockwise turn : Decrease spring tension.
• Mixer assembly
• The air valve mixer is an air-fuel metering device and is completely self-
contained.
• The mixer is an air valve design, utilizing a relatively constant pressure drop
to draw fuel into the mixer from cranking to full load.
• The mixer is mounted in the air stream ahead of the throttle control device.
• When the engine begins to crank it draws in air with the air valve covering
the inlet, negative pressure begins to build.
• This negative pressure signal is communicated to the top of the air valve
chamber through 4 vacuum ports in the air valve assembly.
• A pressure/force imbalance begins to build across the air valve diaphragm
between the air valve vacuum chamber and the atmospheric pressure below
the diaphragm.
• The air valve vacuum spring is calibrated to generate from 101.6 mm (4.0
inches) of water column at start to as high as 355.60 mm (14.0 inches) of
water column at full throttle.
• Pressure Trim and Fuel Trim Valves

• The Pressure Trim Valve (PTV) is directly mounted to the regulator

• This solenoid is a 12 volt normally closed solenoid.
• The function of this solenoid is to regulate a specific amount of venture
vacuum to the atmospheric side of the secondary diaphragm.
• By introducing vacuum to the top side of the secondary diaphragm during
regulator operation the amount of fuel being delivered to the mixer can be
“trimmed” or reduced to allow for correction to the air fuel ratio for closed
loop fuel control.
• The solenoid receives a reference signal from the ECM which causes the
solenoid to be pulsed fast or slow depending on the amount of fuel to be
trimmed.
• Pressure Trim and Fuel Trim Valves

• The Fuel Trim Valve (FTV) is mounted to the Mixer to Throttle control
device adapter
• This solenoid is a 12 volt normally closed solenoid
• The function of this solenoid is to regulate a specific amount of fuel into the
air fuel stream below the mixer
• By introducing additional fuel during certain operating condition the fuel air
ratio can be corrected
• The solenoid receives a reference signal from the ECM which causes the
solenoid to be pulsed fast or slow depending on the amount of fuel to be
trimmed during closed loop operation.
Pressure Trim and Fuel Trim Valves
III. Hydraulic system
Hydraulic pump

1) Front cover
2) Gear plate
3) Rear cover
4) Drive gear
5) Idler gear
6) Bearing
7) Square ring
8) Wear plate
9) Balance seal
10) Back up ring
11) Oil seal
12) Retaining ring
13) Bolt
14) Plain washer
HLF HDF

Machine HDF20/30II HLF20/30II HLF20/30CII HLF15/18II

Pump PHB28RA118 PHB31LA191 PHB31LA192 ☜

TYPE Gear pump ☜ ☜ ☜

Pump Capacity 28.6㎠/REV 31.8㎠/REV ☜ ☜

Flow for Steering 12Liter/Min ☜ ☜ 10Liter/Min

Rotating Direction
C.W. C.C.W. ☜ ☜
of Shaft
Hydraulic tank

▣ Tank Capacity
② HDF20/25/30II,HLF20/25/30II
: 47Liter
HLF20/25/30CII: 47Liter
1) Hyd’ oil cap & Level gauge

③ 2) Breather hose
④ 3) Air Breather
4) Filter (Size: 125μ)
Main control valve

⑨ ⑧
⑦ ⑥
(A)
⑤
④
③
(B)
①
②

1. Main relief valve: 185kg/㎠ A. Main relief pressure check port

2. Steering relief valve: 80kg/㎠ B. Steering relief pressure check port
3. Inlet sector 4. Lift spool section
5. Tilt spool section 6. Aux. spool section
7.8.9. Port relief valve: 150kg/㎠
1) Circuit
2) Inlet section

A. Connector ass’y F. Orifice K. Tank passage

B. Main relief valve (185kg/㎠) G. Damper orifice for ② spool L. Chamber
C. PF port relief valve (80kg/㎠) H. Oil passage M. Damper orifice for 20 piston
D. EF passage (Main) I. Pilot passage
E. Orifice for control stand-by oil flow J. Damper
From Pump To Lift
Spool To Tank

To
Steering
3) Lift section in neutral

Cylinder port (A)

Load check valve
High pressure passage

Neutral passage Low pressure passage

4) Lowering down
Lowering down
5) Lifting up
Lifting up
Down Control & Safety Valve
Down Control
1 Valve

2 Down Safety
Valve
1 : Down control valve : It provides smooth operation while fork lowering.

2 : Down safety valve : It prevents fork from falling suddenly when hydraulic piping
fails unexpectedly.
6) Tilt section in neutral
7) Forward Tilting
Forward Tilting
Dash 5
9) Reverse Tilting
Reverse Tilting
 Dash 5

Hydraulic Circuit
Dash 5
Dash 5
 Dash 5

When the lift control lever is in the lift position

 Dash 5

LIFT POSITION
 Dash 5

When the lift control lever is in the lower position

 Dash 5

LOWER POSITION
 Dash 5

When the Tilt control lever is in the forward position

 Dash 5

Tilt Forward Position

 Dash 5

When the Tilt control lever is in the backward position

 Dash 5

Tilt Backward Position

10) Main relief valve
Sleeve [E] • Inner space(D) is filled with pressurized oil when a
cylinder is working.
Pilot poppet [F] • The pilot poppet(F) holds the oil until it is pushed
open by oil at preset pressure.
• At the moment, the escaping oil makes the pressure in
(D) space lower than that in the HP side.
• Consequently, the higher force at HP side can push
the main poppet(C) against the force at the space (D).
Inner space [D] • Then, oil in HP side return to tank via LP passage.
Main poppet [C]
11) Port relief valve
Relief function
• Relief valve poppet(D) is secured at closed position
by area difference of diameter A and B, for the same
pressure is on the areas.
• When the pressure is raised enough to push the pilot
poppet(E), the pressure on the diameter B becomes
lower than that on the diameter A.
• Then, the force on the diameter A pushes the relief
valve poppet(D) to open passage to LP side.
11) Port relief valve

Make-up function

• When the cylinder port pressure drops ( closer to

negative pressure ) until the cylinder port pressure is
lower than the tank pressure, poppet "B" opens due to
the difference in area between "A" and "B".

• Oil flows from the tank passage to the cylinder port in

order to prevent cavitation.
Steering System

1. Mast

2. Lift Cylinder

3. Control Valve

4. Lever

5. Steering Valve

6. Steering Cylinder

7. Steering Wheel

8. Hydraulic Pump

9. Oil Tank
1) Steering Components
Adjustable Steering Wheel

A : Adjusting Lever

Steering Cylinder
75mm rod x 85mm tube

Capacity : 12 LPM
2) Maintenance for steering axle

Greasing Points

- RH & LH : 5 points/each
- Axle shaft support, Inner & Outer : 1 point/each
- Greasing interval : Once a week

Assembly of king pin bearing

1 2 3 4

D:30 D:32 3
2
1
3) Steering unit
1. Dust seal 2. Housing
3. Ball
4. Thread bushing
5. O-ring 6. Bearing
7. Ring 8. Cross pin
9. Cardan shaft
10. Spring set 11. O-rig
12. Distributor plate
13. Wheel gear 14. O-ring
15. End cover 16. Washer
17. Pin 18. Screw
19. Name plate
20. Relief valve
21. Spring 22. O-ring
23. Ring 24. Check valve
 Steering column

Return Steering
pipe [T] cylinder [R]

Control valve Relief valve

Steering
[P] cylinder [L]
4) Steering Operation

Neutral Left Turning Right Turning

Right Turn
Left Turn
Right Turn
Ⅳ. Power train system
Power train system (Transmission)

Transmission : Maker : Dae Il

Type : Electric power shift
1 : Electric direction control solenoid
2 : Forward/Reverse lever
 Specification of Transmission
Description Description

Model OKAMURA MD14 Type Wet Multi Disc

Type 3 elements, Single Stage, Double Phase Number of Disc 2 X 6 (Psc)

Torque
Converter Stall Torque 2.8 : 1 Clutch Disc Material Fiber

RPM 2140 ±50 rpm Clutch Clearance 1.5 ±0.3mm

Inlet Oil Pressure 2 ~ 7bar Operating Pressure 9.8 ~ 14.9 bar (140 ~210 psi)

Type Power Shift Pump Pressure 9.8 ~ 14.9 bar (140 ~210 psi)

Control
Gears Forward 1, Reverse 1 Speed Valve Clutch Pressure 9.8 ~ 14.9 bar (140 ~210 psi)

Trans-
mission Control Electric gear selector, Kick Dwon Inching Type Mechanical

Forward 17.836 : 1 Shifting Delay 1.0 ~ 1.6 second

Gear Ratio
Reverse 18.317 : 1 Normal Oil Temp. 80 ~ 100㎠

Others Oil Temp. at warning 120 ±3㎠

Oil Level Check : Run engine about 1 minute to fill up toorque
converter. Oil SAE 15W (SAE 10W - 30)
Then, check oil level after turning the engine off.
Oil Capacity 8liter(2.12 gal)
Torque converter
 Spec

2.7kg·m(26.5Nm)

2.1kg·m(20.6Nm)

2.7kg·m(26.5Nm)
Oil flow of torque converter
Hydraulic pressure

Inlet : 3~7 bar, cracking pressure 5 bar

(44~102 psi) (73 psi)
Outlet : 2~5.5 bar, cracking pressure 2.3 bar
(29~80 psi) (33 psi)
Transmission control valve
(1) Sectional View
Forward
Solenoid

Forward
Solenoid
2) Functions

Valve Description Remark

This valve reduces shocking that is created in transmission

when operator changes gear or uses inching function. Useful when abrupt gear
Modulating Valve change is tried.

The forward and reverse coils are located at this valve so

Solenoid Valve that the valve controls forward and reverse travel.

The valve blocks pressure to clutches so that it makes

transmission neutral. All the engine power can be used for Do not use at high travel
Inching Valve lifting and tilting by the valve. speed

The valve regulates pressure to clutches and bypasses

Regulator Valve pressure higher than setting value to protect transmission. Main relief valve
Neutral
P3
P1: Main pressure check port Modulating
Forward valve
P4: Cooling pressure check Solenoid
Solenoid
valve

Forward
Solenoid Inching
valve

P2 R P1
F
Regulator
valve

P5
P4
Neutral

1. In the beginning, oil can

only flow to Ø1.2 orifice
and then piston moves
back due to oil pressure.
2. Eventually oil passage
from Ø1.8 orifice to the
modulation valve is
opened so that pressure
is suddenly increased up
to 10~14bar.
Forward
F : Forward pressure check port
Modulating
P3: Modulating pressure check valve

Solenoid
valve

Inching
valve

Regulator
valve
Forward
Forward & Inching
Reverse

R : Reverse pressure check port Modulating

valve

Solenoid
valve

Inching
valve

Regulator
valve
Reverse
Reverse & Inching
Inching
Modulating
valve

Solenoid
valve

Inching
The operation of inching valve valve
makes the oil flow cut from
charging pump to modulating
valve. Regulator
valve
 Reverse Forward

Forward
『P』

Reverse
Forward

『P』
『T』
Reverse
T/M Control Valve

Air
Breather

Engine & Inching

Torque Spool
Converter

Forward
Solenoid

Reverse
Solenoid
 Pressure check port P7 Bleeder Oil level
P4 P5 dipstick
P4
P5 P1

P1

P7

P6 P6
R P2
F
P3
R P2

P1 : Main pressure (9.8 ~ 14.9 bar) [140 ~ 210 psi] P6 : Converter inlet (3 ~7 bar) [44 ~ 102 psi]
P2 : Inching pressure (9.8 ~ 14.9 bar) [140 ~ 210 psi] P7 : Converter outlet (2 ~5.5 bar) [29 ~ 80 psi]
P3 : Modulating (9.8 ~ 14.9 bar) [140 ~ 210 psi] F : Forward (9.8 ~ 14.9 bar) [140 ~ 210 psi]
P4 : Cooler inlet (Approx 4.5 bar) [64 psi] R : Reverse (9.8 ~ 14.9 bar) [140 ~ 210 psi]
P5 : Cooler outlet (Approx 4.5 bar) [64psi]
Trouble shooting 1
1) Model : HDF20~30-2, HLF20~30-2
2) When : April, 2003
3) Trouble
- Machine traveled normal when oil was cold but
- could not travel at slop and had low travel power when oil was warmed up.
4) Checking results
- T/M OIL LEVEL : Normal
- Warning lamp and sensor for T/M oil temperature : Normal
- T/M Control valve pressure at neutral

Check point SPEC Actual Remark

P1 Charging pump 9.8 ~ 14.9 bar 12bar Normal

P2 Inching valve 9.8 ~ 14.9 bar 4bar T/M oil leaking

P3 Modulating valve 9.8 ~ 14.9 bar 3bar
5) Cause of Trouble
- Foreign material was found lodged at Inching valve.
- Inching spool was locked at middle of stroke even when inching pedal was returned neutral.
- Some oil bypassed and it caused clutches to be engaged not fully.
6) Remedy
- Cleaned T/M Control valve
 Pressure Checking Points

Modulating valve
P3

Solenoid valve P3

Inching valve P2
P2
F R
Regulator valve P1
P1
P5 P4 P4

P5
Trouble shooting 2
1) Model : HDF20~30-2, HLF20~30-2
2) When : June, 2002
3) Trouble
- Reverse travel was not normal while forward travel was good.
- Travel power tended to decrease when oil was warmed up.
4) Checking result
- T/M OIL LEVEL : Normal
- Warning lamp and sensor for T/M oil temperature : Normal
- T/M Control valve pressure at neutral

Check point SPEC Actual Remark

P1 Charging pump 9.8 ~ 14.9 bar 12bar Normal

F Forward clutch 9.8 ~ 14.9 bar 12bar Normal

0bar
R Reverse clutch 9.8 ~ 14.9 bar Abnormal
3~5bar
5) Cause of Trouble
- Open circuit in T/M solenoid coil : Resistance showed unlimited
- However, the resistance showed normal at cold oil and about 3-5Ω was measured
at warm oil.
- So, machine worked normal at initial stage of working but started to show the trouble when oil
was warmed up.

6) Remedy : Reverse coil was replaced.

- Electric for T/M Control Valve

1. Fuse 15A Solenoid coil spec

2. F-R Switch
3. Forward solenoid
4. Reverse solenoid
5. Backup lamp(L/H)
6. Backup lamp(R/H)
7. Backup horn
C. Safety relay

Solenoid Coil Resistance

Spec Act Judge

F 8.8Ω Normal
9Ω
No
R ∝( 3~5Ω)
Good
Trouble shooting 3
1) Model : HDF20~30-2, HLF20~30-2
2) When : April, 2003
3) Trouble
- Machine traveled forward at control lever neutral
4) Checking result
- T/M OIL LEVEL : Normal
- Warning lamp and sensor for T/M oil temperature : Normal
- T/M Control valve pressure at neutral

Actual by engine rpm

Check Point SPEC Remark
Low High

P1 Charging pump 9.8 ~ 14.9 bar 8.5~9bar 12bar Normal

F Forward clutch 9.8 ~ 14.9 bar 8.5~9bar 12bar Normal

R Reverse clutch 9.8 ~ 14.9 bar 8.5~9bar 12bar Normal
 - Cleaning of solenoid valve was no good.
- Replacing of solenoid valve did not work.
- There were no feeling of overload at reverse traveling.
5) Cause of Trouble
- Crack inside T/M control valve formed a oil passage to forward line.
6) Remedy : T/M control valve was replaced.
Trouble Shooting 4
1) Model : HDF30-2 #3229 – 18hrs
2) When : June, 2004
3) Trouble
- Machine started about 5-8 seconds later after lever was put at forward or reverse.
- Machine traveled just a little at low engine rpm on flat ground.
- Machine traveled with low power when engine rpm was increased.
4) Checking result
- T/M OIL LEVEL : Normal
- Engine rpm : Normal
- Forward/reverse lever condition : Normal
- T/M solenoid coil : Normal as 9 Ω
- T/M Control valve pressure at neutral
 - T/M Control valve pressure at neutral
Description Actual by (engine rpm)
SPEC Remark
PORT Check point Neu(LOW) For(LOW) Rev(HIGH)
P1 T/M PUMP 9.8 ~ 14.9 bar 12.4bar 12.5bar 14.5bar

P2 INCHING V/V 9.8 ~ 14.9 bar 12.1bar 12.0bar 14.6bar

P3 MODUATING V/V 9.8 ~ 14.9 bar 1.2bar 3.5bar 3.9bar No good

R Reverse 9.8 ~ 14.9 bar 0.4bar 2.7bar 3.1bar

4) Checking results
- A plastic foreign material was found at 1.2mm orifice that was connected to the modulating valve.
- Inching valve, modulating valve and solenoid valve were fine.

5) Remedy : Cleaned completely the control valve

- T/M CONTROL VALVE

1.4mm oriffice

Modulating
Solenoid valve
valve
1.2mm oriffice

Inching
valve

Regulator
valve
- T/M CONTROL VALVE

1.4mm oriffice

1.2mm oriffice
Drive Axle

1 Axle Oil
- Oil : SAE 90-GL4 for
2 moderate weather
- Oil capacity : 5 liter
- #1 : Breather & oil filler cap
- #2 : Oil level plug
3 - #3 : Oil drain plug
(1) Drive axle
2 1. Housing
2. Cap
3. Plug
4. Brake drum
4 5. Oil seal
3
1
5 6. Bearing
6
7 7. Hub
8. Bearing
9. Plate
10. Nut
11. Oil seal
30 ~ 50㎏·m (98 ~126Nm)
8 12. Shaft
9
10 10 ~ 13㎏·m (32.7 ~42.5Nm)
11

12
(2) Differential
1. Case
2. Case
3. Bolt
4. Spider
5. Pinion gear
6. Waher
7. Side gear
8. Bushing
9. Bevel gear
10. Bolt
11. Bearing
12. Screw
13. Cap
14. Bolt
15. Pin
(3) Adjustment of Differential

Installing Differential

1. Install differential and fit adjusting screw(1).

2. Apply loctite in the hole of cap(2) and temporarily tighten bolt(3).

Loctite #271

Backlash Adjustment

1. Install the dial gauge as illustrated and check backlash.

2. To adjust backlash, loosen adjustment screw(1) at one side by one notch
and tighten the other side screw(1) by one notch.
3. Gradually move differential case this way and watch dial indicator for
correct value.
4. Turn the bevel gear to confirm the backlash at 4 different places.

Adjustment of Side Bearing Preload

Tighten the adjustment screw(1) uniformly at 20 kg-m.

(4) Service References

mm ( in )
Specification
No Check Item Repair limit Remedy
Standard size
Differential pinion Scratch on the
A **Replace.
gear and side gear teeth
24.96 ~ 24.98 24.75
B O.D of spider
(0.984~0.988) (0.974)
I.D of differential 25.0 ~ 25.1 25.2
C
pinion gear (0.984~0.988) (0.992) Replace.
1.94 ~ 2.06 1.7
D Width of bushing
(0.076~0.081) (0.067)
1.52 ~ 1.68 1.3
E Width of bushing
(0.060~0.066) (0.05)
310.0~310.2 312
(I.D of brake drum)
(12.20~12.21) (12.28)
** : Replace bevel gear and pinion as a set unit.
Brake System
Master Cylinder ( Dry Type)

Reservoir Tank

Wheel cylinder
 Brake & Sound

• Better braking performance by Duo Servo

drum brake
• Auto adjusting brake lining system
• Toggle type parking lever for easier operation

* Lowered sound level

At high idle, dynamic condition

HDF20/25/30-2 HDF20/25/30-5

91.3dBA 87.5dBA
V. Electric system
Operating panel 1 : Cooling water temp. gauge

2 : Hour meter
HLF & HDF 20/25/30II
3 : Direction indicator

4 : Fuel gauge

3 5 : Water separator lamp(HDF)

1 4 6 : Fuel level warning lamp

7 : Engine oil pressure warning lamp

2
8 : T/M oil temp. warning lamp

9 : Battery charge warning lamp

7 8 9 10 11
6 12
5 13 10 : Air cleaner filter warning lamp

11: Head light indicator

12: Working light indicator

13: Preheater indicator

Operating panel
1 : Cooling water temp. gauge
HLF20/25/30CII
2 : Fuel gauge

3 : T/M oil temp. warning lamp

3 4 5 6 4 : Engine oil warning lamp

5 : Battery charge warning lamp

1 12 2
6 : Air cleaner filter warning lamp
11 10 9 8
7 7 : Hour meter

8 : Parking lamp

9 : Working light indicator

10: Head light indicator

11: Preheater indicator

12: Direction indicator

Location of Components
HLF & HDF 20/25/30II

2 4 1 6
3

1 : Horn 2 : Relay for back alarm 3 : Relay for back alarm

4 : Flash unit 5 : Start key switch 6 : Back up buzzer
7 : Fuse box
HDF20/25/30II

Starting System
HDF20/25/30II
Panel Circuit
HDF20/25/30II
Lamp Circuit
HDF20/25/30II

Lamp Circuit
Power Circuit
Starting Circuit( Key On)
Starting Circuit
HLF20/25/30CII
Starting Circuit

1. Battery
2. Master switch
3. Start motor
4. Start relay
5. Safety relay
6. Fusible link 50A
7. Start switch
8. Fuse 10A
9. Fuse 10A
10. Distributor
11. Fuel cut solenoid
HLF20/25/30CII
Panel Circuit

1. Alternator 2. Fuse 10A 3. Fuse 7.5A

4. Operator panel 5. Water temp sensor 6. Fuel level sensor
7. Parking switch 8. Engine oil pressure switch 9. T/M oil temperature sensor
HLF20/25/30CII
Head & Working Lamp Circuit

1. Fuse 15A
2. Head tail lamp switch
3. Front tail lamp, LH
4. Front tail lamp, RH
5. Rear tail lamp, LH
6. Rear tail lamp, RH
7. License lamp(option)
8. Head lamp relay
9. Head lamp, LH
10. Head lamp, RH
11. Fuse 10A
12. Working lamp s/w(option)
13. Working lamp(option)
HLF20/25/30CII
Travel Circuit

1. Fuse 15A
2. F-R switch
3. Forward solenoid
4. Reverse solenoid
5. Back lamp, LH
6. Back lamp, RH
7. Back horn
HLF20/25/30CII
Combination Lamp Circuit

1. Fuse 15A
2. Flash unit
3. Turn signal switch
4. Hazard s/w(option)
5. Front turn lamp, LH
6. Rear turn lamp, LH
7. Front turn lamp, RH
8. Rear turn lamp, RH
9. Fuse 7.5A
10. Brake switch
11. Brake lamp, LH
12. Brake lamp, RH
13. Fuse 10A
14. Horn
15. Horn switch