HDF20 25 30-5

CONTENTS
SECTION 1 GENERAL
Group 1 Safety Hints 1-1
Group 2 Specifications 1-5
Group 3 Periodic Replacement 1-13
SECTION 2 REMOVAL AND INSTALLATION OF UNIT

Group 1 Structure 2-1
Group 2 Removal and Installation of Unit 2-2
SECTION 3 POWER TRAIN SYSTEM

Group 1 Structure and Operation 3-1
Group 2 Troubleshooting 3-15
Group 3 Tests and Adjustments 3-19
Group 4 Disassembly and Assembly 3-23
SECTION 4 BRAKE SYSTEM

Group 1 Structure and Function 4-1
Group 2 Operational Checks and Troubleshooting 4-6
Group 3 Tests and Adjustments 4-9
SECTION 5 STEERING SYSTEM

SECTION 6 HYDRAULIC SYSTEM

SECTION 7 ELECTRICAL SYSTEM

Group 1 Component Location 7-1
Group 2 Electrical Circuit 7-2
Group 3 Component Specification 7-9
Group 4 Troubleshooting 7-12
SECTION 8 MAST
Group 1 Structure 8-1
Group 3 Adjustment 8-8
Group 4 Removal and Installation 8-11
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.
This section explains the structure of the transmission as well as control valve and drive axle.
This section explains the brake piping, each component and operation.
This section explains the structure of the steering unit, priority valve, trail axle as well as steering
circuit and operation.
This section explains the structure of the gear pump, main control valve as well as work equipment
circuit, each component and operation.
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(①②③…)
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
※ Caution
other precautions for preserving
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 ⓐ, then draw a
horizontal line from ⓐ.
(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 ⓒ. This point ⓒ 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
ⓒ
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
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 1ℓ = 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 1ℓ = 0.21997 U.K.Gal
0 1 2 3 4 5 6 7 8 9
0 0.220 0.440 0.660 0.880 1.100 1.320 1.540 1.760 1.980

10 2.200 2.420 2.640 2.860 3.080 3.300 3.520 3.740 3.950 4.179
20 4.399 4.619 4.839 5.059 5.279 5.499 5.719 5.939 6.159 6.379
30 6.599 6.819 7.039 7.259 7.479 7.969 7.919 8.139 8.359 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
kgf·m to lbf·ft 1kgf·m = 7.233lbf·ft
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
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
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.
。C 。F 。C 。F 。C 。F 。C 。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
SECTION 1 GENERAL
Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1

Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
Group 3 Periodic Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-13
GROUP 1 SAFETY HINTS
Careless performing of the easy work may cause injuries.

Take care to always perform work safely, at least observing the following.
· Oil is a dangerous substance. Never handle
oil, grease or oily clothes in places where
there is any fire of flame.
As preparation in case of fire, always know
the location and directions for use of fire
extinguishers and other fire fighting equipment.
D35ASF01
· 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.
D35ASF02
· Flames should never be used instead of

lamps. Never use a naked flame to check
leaks or the level of oil or electrolyte.
D35ASF03
· Exhaust gas is dangerous. Provide adequate

ventilation when working a closed space.
D35ASF04
1-1
Be particularly careful when removing the
radiator cap and the hydraulic oil tank filler
cap, if this is done immediately after using the
machine, there is a danger that boiled oil may
spurt out.
· The procedure for releasing the hydraulic
pressure is as follows : lower the fork to the ground,
and stop the engine(Motor), move the control
levers to each position two or three times.
D35ASF05
· When working on top of the machine, be

careful not to lose your balance and fall.
D35ASF06
· 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 the engine is
running.
D35ASF07
When inspecting the engine is running parts, or

near such parts, always stop the engine first.
Before checking or servicing accumulator or
piping, depress brake pedal repeatedLy to
release pressure.
· Park the machine on firm, flat ground.
Lower the fork to the ground and stop the
engine.
Return each lever to NEUTRAL and apply the
D35ASF08
brake lock.
1-2
· 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
D35ASF09
· When working with others, choose a group

leader and work according to his instructions.
Do not perform any maintenance beyond the
agreed work.
D35ASF10
· 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.
· 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.
D35ASF11
1-3
· Thoroughly clean the machine. In particular, be careful to clean the filler caps, grease fittings and the
area around the dipsticks. Be careful not to let any dirt or dust into the system.
· Always use HYUNDAI Forklift genuine parts for replacement.
· Always use the grades of grease and oil recommended by HYUNDAI Forklift.
Choose the viscosity specified for the ambient temperature.
· Always use pure oil or grease, and be sure to use clean containers.
· When checking or changing the oil, do it in a place free of dust, and prevent any dirt from getting into
the oil.
· Before draining the oil, warm it up to a temperature of 30 to 40。C .
· After replacing oil, filter element or strainer, bleed the air from circuit.
· When the strainer is located in the oil filler, the strainer must not be removed while adding oil.
· When changing the oil filter, check the drained oil and filter for any signs of excessive metal particles
or other foreign materials.
· When removing parts containing O-ring, gaskets or seals, clean the mounting surface and replace
with new sealing parts.
· After injecting grease, always wipe off the oil grease that was forced out.
· Do not handle electrical equipment while wearing wet places, as this can cause electric shock.
· During maintenance do not allow any unauthorized person to stand near the machine.
· Be sure you fully understand the contents of the operation. It is important to prepare necessary tools
and parts and to keep the operating area clean.
· When checking an open gear case there is a risk of dropping things in. Before removing the covers to
inspect such cases, empty everything from your pockets. Be particularly careful to remove wrenches
and nuts.
· Way to use dipstick
Push the dipstick fully into the guide, and then pull out.
Carrying out other difficult maintenance work carelessly can cause unexpected accidents. If you
consider the maintenance is too difficult, always request the HYUNDAI Forklift distributor to carry out it.
1-4
GROUP 2 SPECIFICATIONS
1. GENERAL LOCATIONS
9 8
10
11
1 16
2 13
3
4 12
14
15
D255GE01
1 Mast 7 Forks 12 Bonnet

2 Lift chain 8 Overhead guard 13 Counterweight
3 Lift cylinder 9 Turn signal lamp 14 Rear wheel
4 Backrest 10 Head lamp 15 Front wheel
5 Tilt cylinder 11 Operator's seat 16 Rear combination lamp
6 Carriage
1-5
2. SPECIFICATIONS
C' C
D
R
A
E
M'
I
H
W
B
J
F
K
T
G L
D255SP01
Model Unit HDF 20-5 HDF 25-5 HDF 30-5
Capacity kg 2000 2500 3000

Load center R mm 500 ← ←
Weight(Unloaded) kg 3440 3800 4300
Lifting height A mm 3300 ← ←
Free lift B mm 155 ← ←
Fork Lifting speed(Unload/Load) mm/sec 700/680 700/670 580/530
Lowering speed(Unload/Load) mm/sec 450/500 ← ←
L×W×T L,W,T mm 1050×100×45 ← 1050×125×45
Tilt angle (forward/backward) C/C’ degree 6/10 ← ←
Mast Max height D mm 4485 ← ←
Min height E mm 2175 ← 2190
Travel speed km/h 18.9 ← 19.8
Body Gradeability degree 19.0 16.8 13.4
Min turning radius(Outside) F mm 2273 2325 2380
Operating hydraulic pressure kgf/cm 2 200 ← ←
ETC Hydraulic oil tank ℓ 50 ← ←
Fuel tank ℓ 64 ← ←
Overall length G mm 2550 2605 2675
Overall width H mm 1160 ← 1235
Overhead guard height I mm 2180 ← 2195
Ground clearance J mm 100 115 130
Wheel base K mm 1650 ← ←
Wheel tread(front/rear) M, M' mm 965/1003 ← 1005/1003
1-6
3. SPECIFICATION FOR MAJOR COMPONENTS
1) ENGINE
ITEM UNIT SPECIFICATION
Model - YANMAR 4TNE98-HYF(IDI)

Type - 4-cycle, in-line overhead valve
Cooling Method - Water cooling
Number of cylinders and arrangement - 4 cylinders, in-line
Firing order - 1-3-4-2
Combustion chamber type - In-direct injection
Cylinder bore X stroke mm(in) 98×110
Piston displacement cc(cu in) 3319(202.5)
Compression ratio - 18.6 : 1
Rated gross horse power ps/rpm 62/2300
Maximum gross torque at rpm kgf·m/rpm 20.3±0.5/1700
Engine oil quantity ℓ(U.S.gal) 7.5(1.9)
Dry weight kg(lb) 225
High idling speed rpm 2575
Low idling speed rpm 750
Rated fuel consumption g/ps.hr 195
Starting motor V-kW HITACHI 12V, 2.3kW
Alternator V-A DENSO 12V, 40A
Battery V-AH 12V, 90AH
Fan belt deflection mm(in) 8~12(0.31~0.47)
2) MAIN PUMP
Type - Fixed displacement gear pump

Capacity cc/rev 27
Maximum operating pressure bar 230
Rated speed (Max/Min) rpm 3000/500
3) MAIN CONTROL VALVE

Type - Sectional
Operating method - Mechanical
Relief valve pressure(Main/Aux) bar 200/150
Flow capacity lpm 90
1-7
4) POWER TRAIN DEVICES
Item Specification
Type 3 Element, 1 stage, 2 phase

Torque converter
Stall ratio 2.8
Type Power shift
Gear shift(FR/RR) 1/1
Transmission Adjustment Electrical single lever type, kick-down system
FR 16.028 : 1
Overhaul ratio
RR 18.317 : 1
Type Front-wheel drive type, fixed location
Axle
Gear Hypoid gear type
Qty(FR/RR) Single : 2/2, Double : 4/2
2.0, 2.5 7.0-12-12 PR, Double : 6.0-15-10 PR
Front(drive)
Wheels 3.0 Single : 28x9-15-12 PR, Double : 6.0-15-10 PR
2.0, 2.5 6.00-9-10 PR
Rear(steer)
3.0 6.5-10-10 PR
Front wheel, duo-servo & auto adjustment type(Dry)
Travel
Brakes Wet disc brake(Option)
Parking Toggle, internal expanding mechanical type
Type Full hydraulic, power steering
Steering
Steering algle 77.8°to both right and left angle, respectively
1-8
4. TIGHTENING TORQUE OF MAJOR COMPONENTS
NO ITEMS SIZE kgf·m lbf·ft
1 Engine mounting bolt, nut M16×2.0 7.5 54

Engine
2 Radiator mounting bolt, nut M10×1.5 6.9±1.4 50±10
3 Torque converter mounting bolt M10×1.5 6.9±1.4 50±10
Hydraulic
4 MCV mounting bolt, nut M10×1.5 6.9±1.4 50±10
system
5 Steering unit mounting bolt M10×1.5 6.9±1.4 50±10
6 Transmission mounting bolt, nut M12×1.75 12.8±3.0 93±22
7 Drive axle mounting bolt, nut M12×1.75 12.8±3.0 93±22
Power
8 train Steering axle mounting bolt, nut M20×2.5 58±8.7 420±63
system Front wheel mounting nut M20×1.5 28±3 203±22
9
10 Rear wheel mounting nut M14×1.5 21±3 152±22
11 Counterweight mounting bolt M30×3.0 215±33 1555±239
12 Others Operator's seat mounting nut M 8×1.25 2.5±0.5 18.1±3.6
13 Head guard mounting bolt M12×1.75 12.8±3.0 93±22
1-9
5. TORQUE CHART
Use following table for unspecified torque.
1) BOLT AND NUT
(1) Coarse thread
8T 10T
Bolt size
kgf·m lbf·ft kgf·m lbf·ft
M 6×1.0 0.85 ~ 1.25 6.15 ~ 9.04 1.14 ~ 1.74 8.2 ~ 12.6
M 8×1.25 2.0 ~ 3.0 14.5 ~ 21.7 2.7 ~ 4.1 19.5 ~ 29.7
M10×1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60.0
M12×1.75 7.4 ~ 11.2 53.5 ~ 81.0 9.8 ~ 15.8 70.9 ~ 114
M14×2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 163
M16×2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18×2.0 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 344
M20×2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22×2.5 48.3 ~ 63.3 349 ~ 458 65.8 ~ 98.0 476 ~ 709
M24×3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30×3.0 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1656
M36×4.0 174 ~ 236 1261 ~ 1704 250 ~ 310 1808 ~ 2242
(2) Fine thread

8T 10T
Bolt size
kgf·m lbf·ft kgf·m lbf·ft
M 8×1.0 2.2 ~ 3.4 15.9 ~ 24.6 3.0 ~ 4.4 21.7 ~ 31.8
M10×1.2 4.5 ~ 6.7 32.5 ~ 48.5 5.9 ~ 8.9 42.7 ~ 64.4
M12×1.25 7.8 ~ 11.6 56.4 ~ 83.9 10.6 ~ 16.0 76.7 ~ 116
M14×1.5 13.3 ~ 18.1 96.2 ~ 131 17.9 ~ 24.1 130 ~ 174
M16×1.5 19.9 ~ 26.9 144 ~ 195 26.6 ~ 36.0 192 ~ 260
M18×1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20×1.5 40.0 ~ 54.0 289 ~ 391 53.4 ~ 72.2 386 ~ 522
M22×1.5 52.7 ~ 71.3 381 ~ 516 70.7 ~ 95.7 511 ~ 692
M24×2.0 67.9 ~ 91.9 491 ~ 665 90.9 ~ 123 658 ~ 890
M30×2.0 137 ~ 185 990 ~ 1339 182 ~ 248 1314 ~ 1796
M36×3.0 192 ~ 260 1390 ~ 1880 262 ~ 354 1894 ~ 2562
1-10
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 18 130.2
1" 41 21 151.9
1-1/4" 50 35 253.2
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 18 130.2
1-7/16-12 41 21 151.9
1-11/16-12 50 35 253.2
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 18 130.2
1" 41 21 151.9
1-1/4" 50 35 253.2
1-12
6. RECOMMENDED LUBRICANTS
Use only oils listed below or equivalent.
Do not mix different brand oil.
Capacityℓ(U.S.gal) Ambient temperature 。
C (。
F)
Service Kind of
point fluid -20 -10 0 10 20 30 40
HDF20/25/30-5
(-4) (14) (32) (50) (68) (86) (104)
SAE 30
SAE 10W
Engine oil Engine oil 8.0
pan (2.1)
SAE 10W-30
SAE 15W-40
Torque ATF 10
converter DEXRON III
transmission Engine oil (2.6)
SAE 80W-90/API GL-5(DRY)

Axle Gear oil 5
(1.3)
TRANSMISSION MP(WET)
ISO VG32
Hydraulic Hydraulic 50
(12.4) ISO VG46
tank oil
ISO VG68
ASTM D975 No.1

Fuel tank Diesel fuel 64
(12.4)
ASTM D975 No.2
Fitting NLGI No.1

Grease -
(Grease nipple)
NLGI No.2
Brake DOT III(DRY)

reservoir Brake oil 0.5
tank (0.13)
AZOLA ZS10(WET)
Radiator
Antifreeze:Water 17 Ethylene glycol base permanent type
50:50 (4.5)
NOTES :
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 CC is used instead of class CD engine oil, the frequency
of oil change must be doubled.
1-12
GROUP 3 PERIODIC REPLACEMENT
For operation safety, never fail to perform periodic maintenance or make periodic replacement of the
consumable parts listed in the following.
These parts may deteriorate in time and are susceptible to wear. It is difficult to estimate the degrees
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).
※ Replacement of consumable service parts in not covered under warranty.
No Description Period of replacement
1 Master cylinder and wheel cylinder caps, dust seals Every 1 year
2 Brake hose or tube Every 1 or 2 years
3 Brake reservoir tank and tube Every 2 to 4 years
4 Power steering hose Every 2 years
5 Stop lamp switch(oil pressure type) Every 2 years
6 Fuel hose Every 2 to 4 years
7 Rubber parts of power steering Every 2 to 4 years
8 Lift chain Every 2 to 4 years
9 Hose of load handling Every 1 or 2 years
1-13
SECTION 2 REMOVAL AND INSTALLATION OF UNIT
Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1

Group 2 Removal and Installation of Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
SECTION 2 REMOVAL & INSTALLATION OF UNIT
GROUP 1 STRUCTURE
21
22 23
20
2 17
24
3
5 18
4 19
7 8 9 10 11 12 14 16 13 15
D255RE01
1 Mast 9 Transmission 17 Muffler

2 Lift cylinder 10 Torque converter 18 Counterweight
3 Carriage & backrest 11 Engine 19 Radiator
4 Tilt cylinder 12 Air cleaner 20 Seat
5 Main control valve 13 Steering cylinder 21 Overhead guard
6 Fork 14 Hydraulic pump 22 Steering wheel
7 Front wheel 15 Steering axle 23 Silencer
8 Drive axle 16 Rear wheel 24 Steering unit
2-1
GROUP 2 REMOVAL AND INSTALLATION OF UNIT
Remove and install following units as explained in the flow chart.
1. MAST
1) REMOVAL
(1) Forks
Anchor pin
① Lower the fork carriage until the forks are
Carriage
approximately 25mm(1in) from the floor.
② Release fork anchor pins and slide one Backrest
fork at a time toward the center of the
carriage where a notch has been cut in
the bottom plate for easy removal. Fork
③ Remove only one fork at a time.
On larger forks it may be necessary to Center notch
use a block of wood.
D255RE02
(2) Piping
① Remove bolts securing backrest to fork
Carriage
carriage. Lift backrest straight up and
remove it from carriage. Backrest
Bolt
D255RE03
(3) Carriage
① With the mast vertical, raise the carriage
high enough to place blocks under the
load forks. This is done to create slack in
the load chains when the carriage is
lowered. Lower the carriage all the way
down to the floor. Make sure the carriage
is level, this will prevent any binding when
the mast is raised. D255RE04
2-2
② While supporting lift chains, remove the
split pins and slide out chain anchor pins
from the chain anchors of stationary Outer mast
upright.
Lift chain Split

pin
Chain
anchor
pin
D255RE05
③ Pull the chains out of the sheaves and

drape them over the front of the carriage. Mast
Carriage &
backrest
Lift chain
Block D255RE06
④ Slowly raise inner mast upright until mast

clears top of fork carriage. Move carriage
to work area and lower the mast. Inner mast
Make sure that carriage remains on
floor and does not bind while mast is
being raised.
⑤ Inspect all parts for wear or damage. Carriage &
Replace all worn or damaged parts. backrest
Lift chain
D255RE07
2-3
(4) PIPING
① Remove the return hoses and clamps
attached to the cylinder.
② Remove the return hoses from the
connector. Band
clamp Hose
③ Remove hose assembly, connector, Return
clamp
down safety valve from the lift cylinder. hose

④ Disconnect hose assembly from the flow
regulator. Lift
cylinder Return
hose
Hose
assy D255RE08
(5) LIFT CYLINDER

Stud
① Loosen hexagonal bolts and remove bolt
washers securing the lift cylinders to
inner mast. Inner
② Bind the lift cylinder with overhead hoist mast
rope and pull up so that the rope has no
slack or binding.
Make sure that the lift cylinder be
tightened firmly for safety. LIft
Cylinder cylinder
③ Loosen and remove hexagon nuts and
band
cylinder band securing cylinder to outer Outer
mast
mast.
④ Using an overhead hoist, slowly raise the
inner mast high enough to clear lift
cylinder.
⑤ Using an overhead hoist, draw out lift
cylinder carefully and put down on the Bolt
work floor. D255RE09
2-4
(6) INNER MAST
① Using an overhead hoist raise the inner
mast straight and carefully draw out of
outer mast section.
Be careful the mast not to swing or fall.
Inner
mast
Outer
mast
D255RE10
(7) TILT CYLINDER PIN

(8) MAST SUPPORT CAP
① Attach a crane to the stay at the top of
the outer mast, and raise enough to
sustain jacked up machine.
※ This operation is carried out from
under the machine, so use a pit, or if Outer
mast
there is no pit, jack up the machine
and loosen with on impact wrench. Tilt
cylinder
② Remove the mounting bolts from the cap
then slowly raise the outer mast.
Pin
Mounting
bolt
Mast
Bushing support cap
D255RE11
2-5
2) INSTALLATION
After assembling mast components totally without piping connections, install mast assembly to the
equipment.
※ Installation procedure for each of mast component is the reverse of the removal procedure.
(1) MAST SUPPORT CAP
① Check the mast support cap and spring pin for wear.
② Jack up the machine so that the front is raised and then using an overhead hoist assemble outer
mast to drive axle unit.
③ Tighten mounting bolts to mast support cap.
·Tightening torque :
(2) TILT CYLINDER PIN
Hold the mast with a crane, operate the tilt control lever and aligh the holes, then knock the pin.
(3) LIFT CYLINDER INSTALLATION AND ADJUSTMENT
① Assemble the lift cylinder inside the outer
mast, then tighten the stopper bolt. If the
cylinder assembly has been replaced,
adjust as follows so that the left and right
cylinders are synchronized at the
maximum lifting height.
② Assemble the cylinder rod to the inner
mast, and check the left-to-right play of
the mast at the maximum lifting height.
※ If play is to LEFT, install adjustment
shim to LEFT cylinder.
※ If play is to RIGHT, install adjustment

L15C3RE12
shim to RIGHT cylinder.
·Shim thickness : 1.0mm(0.04in)
2-6
2. POWER TRAIN ASSEMBLY
1) REMOVAL
B153RE00
(1) Mast
Refer to section on mast.
(2) Brake piping and T/M cooling piping

Disconnect the brake pipes and T/M Brake
cooling pipes from powerline assembly. Brake master
pipe cylinder
Powerline T/M cooling

assembly pipe
D255RE13
(3) Parking brake cable

Disconnect parking brake cable from the
wheel brake assembly.
D255RE14
(4) Flexible plate

Remove the cover on the top face of the
torque converter housing then remove the T/C cover
8 mounting bolts installed to the engine Mounting

bolt
flywheel.
To rotate the flywheel, remove 1 mounting Engine
bolt, then insert a turning tool in the
mounting hole. One man must turn the
engine fan by hand while the other turns
Powerline
the flywheel. assembly
D255RE15
2-7
(5) Powerline assembly Crane
① Attach a crane to the filt cylinder notches Dashboard
on the dashboard and raise the machine Powerline Mounting bolt
assembly
enough for truck to slide under powerline
assembly. Frame
② Put the block between the truck and

powerline assembly.
Support cap
D255RE16
③ Remove drive axle mounting bolts from

the frame and then slowly pull out the
truck.
2) INSTALLATION
Installation is the reverse order of removal,
but be careful of the following points.
(1) Tightening torque of mounting bolt for
powerline assembly.
·19.6kgf·m(142lbf·ft) Crane
Mounting
bolt
Dashboard
T/C cover
Frame
Support cap
Mounting bolt
Powerline
assembly
D255RE17
2-8
3. ENGINE
Lever the torque converter, transmission and drive axle inside the frame, the remove the engine
assembly.
1) REMOVAL
(1) Overhead guard
Remove the wiring for rear combination
lamp, working lamp, head lamp and
Crane
flasher lamp on the stay of the overhead
guard and then raise it together with the
bonnet.
Overhead guard
D255RE18
(2) Floor plate

Uncover the floor mat first and then loosen
Floor mat
the mounting bolts to remove the floor
plate.
Mounting
bolt
Floor plate
Sponge
Frame
D255RE19
2-9
(3) Engine accessory
Radiator
Remove all wiring harnesses, cables and
hoses between the engine and the
dashboard and frame.
Hose
① Wiring harness to alternator and starter.
Engine
② Wiring harness for oil pressure and assembly
engine water.
Overflow
hose
Reservoir
tank
D255RE20
(4) Radiator hose

Open the drain valve of the radiator and
drain the cooling water, then remove the
radiator hose.
(5) Mounting bolt

Attach a crane to the engine hook and
raise, then remove the left and the right
Mounting
mounting bolts. Raise the engine slightly, bolt
sliding towards the radiator, then lift up.
※ When sliding the engine, if it hits the
radiator it will damage the radiator, so it
is better to remove the radiator if
possible.
Engine assembly
D255RE21
2-10
2) INSTALLATION
Installation is in the reverse order to Loctite #243
removal, but be careful of the following 5.5-8.3kgf.m
points. (40~60 lbf.ft)
(1) Tighten the engine mounting bolts and Mounting bolt

7.5kgf.m(54.2lbf .ft)
nuts.
(2) Tighten the engine mounting bracket bolts.
Do not remove the bolts unless necessary.
Shim
※ Loctite is coated on the thread of bolt.
So if the bolts must be removed, coat Nut
the loctite(#243) when installing.

※ Before installing the bolts, loctite in the D255RE22
holes should be removed by a tap.
(3) Tightening torque of mounting bolt

installing. Muffler
·7.5kgf·m(54.2lbf·ft)
(4) Radiator hoses
·Distance to insert hose : 40mm(1.57in)
(5) Air cleaner hose
Insert the air cleaner hose securely and fit
a clamp.
Distance to insert hose
·Air cleaner hose : 40mm(1.57in) Air cleaner
·Engine end : 20mm(0.8in)
Engine assembly
D255RE23
2-11
4. WHEEL BRAKE
1) REMOVAL
(1) Front wheel
Put a block under the mast and tilt
forward, or jack up the bottom of the frame
to raise the front wheels off the ground,
then loosen the hub nuts to remove
wheels.
Hub nut
D255RE24
(2) Brake, drum assembly

The oil seal inside the hub acts as a seal
for the axle shaft end. Therefore when
removing or installing the brake and drum
assembly, remove or install in a straight Wheel brake
line to prevent twisting the seal up and Drum
down or to the right and left. Oil seal
Bearing
Hub
D255RE25
2) INSTALLATION
Installation is in the reverse order to
Wheel brake
removal, but be careful of the following
points.
Drive axle
(1) Coat the mounting bolts with loctite and
tighten to 19.6kgf·m(141lbf·ft).
Drum
Mounting bolt
D255RE26
(2) When replacing the oil seal inside the hub,

be careful to install the seal in the correct
direction(Lip on outside) and knock into
place.
L15C3RE27
2-12
(3) Wipe the inside of the brake drum clean,
coat the lip of the seal with grease, and
assemble the brake and drum assembly.
Adjust a spring balance to the hub bolt
Spring balance
and adjust the nut to give a starting force
of 12 to 20kgf(27~44lbf).
Measuring starting
torque
L15C3RE28
(4) Tightening torque of hub nut for front

wheel.
·35kgf·m(253lbf·ft)
Coat the hub bolt with molybdenum
disulphide.
2-13
5. REAR AXLE
1) REMOVAL
Mounting bolt
Counterweight
D255RE29
(1) Counterweight
Install a lifting tool in the hole in the counterweight, and raise it with a crane.
Remove the mounting bolts and raise the counterweight slightly and move it to the rear side.
· Weight of counterweight(standard)
HDF20-5 : 1170kg(2580lb)
HDF25-5 : 1470kg(3240lb)
HDF30-5 : 1800kg(3970lb)
2-14
(2) Rear wheels
※ Before removing rear wheels lift up the
rear side with a crane or jack up. Rear wheel
Remove cap, split pin and then loosen
castle nut.
Take out rear wheel assembly with Wheel hub Castle
Taper
taper roller bearing and oil seal. nut
roller
bearing
Cap D255RE30
(3) Hose
Drain hydraulic oil in the hoses and Steering axle
cylinder before removing them. RH
Loosen long connector and then

LH
disconnect the hoses.
Hose assy
D255RE31
(4) Mounting bolts

Put a block under the steering axle, Trunnion
block Truck
support on a truck and raise the frame
with a crane. Steering
axle
Remove the mounting bolts installed to
the frame, and pull out to the rear.
※ There are shims between the trunnion
block and the steering axle to prevent
play.
D255RE32
2-15
Group 1 Structure and Operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1

Group 2 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-15
Group 3 Test and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-19
Group 4 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-23
GROUP 1 STRUCTURE AND OPERATION
1. POWER TRAIN DIAGRAM
The TORQFLOW transmission uses one-speed forward and one-speed reverse transmission.
The torque converter, differential, and final drives are strengthened to match them with increased
engine output and machine traveling performance.
1 2 3
D255PT26
1 Brake drum 4 Transmission 6 Torque converter

2 Brake 5 Hydraulic gear pump 7 Engine
3 Drive axle
3-1
2. INSTALLATION VIEW
4
5
1
2
D255PT05
1 Control valve 3 Oil filter 5 Temperature sender

2 Dipstick 4 Air breather
3-2
3. TRANSMISSION
1) TORQUE CONVERTER
The torque converter is directly bolted to the engine flywheel housing.
Engine output is delivered from the flywheel to the flexible plate.
(1) Structure
Ball bearing
1
Output pressure
adjusting valve spring
Gear pump assembly

Inlet relief valve spring
Converter
Input guide
3 6
2
5
D153PT27
1 Turbine shaft ·3-element, 1-stage, 2-phase

2 Stator ·Stall speed : 3500rpm
3 Impeller ·Maximum input pressure : 7kgf/cm2
4 Housing
5 Flexible plate
6 Turbine
3-3
(2) Hydraulic circuit
Torque converter assy Torque

converter
T P
Inlet port S Outlet port

To control valve
Inlet pressure Outlet pressure
detector port G detector port
Main relief valve F
C I
To cooler
Gear pump
A D E H
Drain Drain
Strainer
L15C3TC11
3-4
2) TORQFLOW TRANSMISSION
5 2 1 3
F R
A
F R
8 12
F
R
11
9 4 A
10
SECTION A - A
F R
Hydraulic clutch
GEAR
Center line
Gear forward RATIO 16.028 18.317
of engine
Hypoid pinion
Clutch Hypoid pinion
Gear forward
Gear
Center line of differential
D255PT01
1 Torque converter 5 Hydraulic clutch 9 Hypoid gear set

2 Pump 6 Forward shaft 10 Differential
3 Torque converter housing 7 Forward gear 11 Drive gear
4 Transmission case 8 Forward gear 12 Stator shaft
3-5
3) OPERATION
The torque converter consists of three elements; an impeller wheel connected to the input side and
a turbine wheel and stator wheel connected to the output side. The torque converter is filled with
oil. The engine rotates the impeller wheel and the impeller blade will give the fluid energy. Oil
flows out along the path by centrifugal force, and this energy will give the turbine wheel torque. The
fluid passing through the rotating turbine wheel generates counter torque of the stator while its flow
is changed by the stator. Counter torque is added to the turbine, and as the result of this, the output
torque is increased several times as engine torque.
The torque converter gives the maximum output torque when the truck starts running. When the
truck runs at high speed, high torque is not required and output torque is gradually reduced. Since
the engine and driven axle are connected through the fluid, return vibrations or shocks from the
axle is absorbed and the longevity of the power transmission system is extended. Truck speed
cannot cause the engine to stall. Torque is automatically converted according to the trucks speed.
This makes the drive operation much easier and work can be done more efficiently.
The power of the engine is transferred from the turbine shaft to the clutch shaft through the torque
converter, and the forward/reverse rotation is selected by the hydraulic clutch. The power is
transferred from the forward drive gear to the driven gear of the hypoid pinion through the drive
shaft and gear. For reverse, the power is transferred from the reverse drive gear of the clutch to the
driven gear of the hypoid pinion through the reverse shaft and gear, drive shaft and gear to
reversely rotate the pinion.
3-6
4) TRANSMISSION OPERATING MODES
(1) Forward
1 2 3
R F
INPUT
REV FWD
OUTPUT
4 5 6
D255PT02
In forward the torque converter is turned by the engine. The torque converter turbine shaft turns the
forward/reverse clutch pack shaft(1) and clutch packs at turbine speed. The piston in the forward
clutch pack(2) is pressurized by transmission fluid from the control valve. The piston applies
pressure to the discs in the clutch pack, causing the clutch to engage. As the clutch engages, it
turns the low forward output gear(3). The low forward output gear engages the forward shaft gear
and turns the forward shaft. The gear on the other end of the forward shaft engages the pinion
shaft spur gear(4) which turns the pinion shaft and pinion gear(5). The pinion gear then turns the
ring gear(6) in a forward direction, moving the machine forward.
3-7
(2) Reverse
1 3
R F
INPUT
REV FWD
OUTPUT
4 5 6
D255PT04
In reverse the torque converter is turned by the engine. The torque converter turbine shaft turns the
forward/reverse clutch pack shaft(1) and clutch packs. The piston in the reverse clutch pack(2) is
pressurized by transmission fluid from the control valve. The piston applies pressure to the discs in
the reverse clutch pack, causing the clutch to engage. As the clutch engages, it turns the reverse
output gear(3), the reverse output gear engages the pinion shaft spur gear(4), turning the spur gear,
the pinion shaft, and the pinion gear(5). The pinion gear then turns the ring gear(6) in a rearward
direction moving the truck in reverse.
3-8
4. CONTROL VALVE
1) STRUCTURE
17 18 19 16 32 20
15 A
C B
33
1
21
28
29
C
30
B 31
11
22
25
23
27
26 24
R
8,9 F 2
7
3
10 A
4
(From COOLER) (To COOLER)
6 12
13
35 34 SECTION A-A 14 5
38 36
37
F R
D153PT28
1 Body 14 Spring 27 Snap ring

2 Plug 15 Plug 28 Valve
3 Piston 16 Piston 29 Spring
4 Valve 17 Stopper 30 Stopper
5 Stopper 18 Spring 31 Nut
6 Valve 19 Spring 32 Screw
7 Plate 20 O-ring 33 Screw
8 Washer 21 Solenoid valve 34 Nipple
9 Bolt 22 Oil seal 35 Spring washer
10 O-ring 23 Plug 36 Plug
11 O-ring 24 Spring 37 Washer
12 Spring 25 Spool 38 Plug
13 Spring 26 Plate
3-9
2) HYDRAULIC CIRCUIT
Reverse clutch Forward clutch
Control valve
F
R
Directional
valve
P3
Accumulator
valve
1.2 1.6
P2
Inching valve Pedal

P1
Main relief
Engine
valve
13.2 cc/rev
2
10.8~14.9 kgf/cm
To control valve
D153PT11
3) OPERATION
The control valve mainly consists of the main relief valve, inching valve, accumulator valve and
directional valve.
The discharged oil from the gear pump enters main relief valve of the control valve and its pressure
is adjusted 10.8~14.9kgf/cm2 (153.6~211.9psi).
The oil sent from the main relief valve flows into the torque converter. The main relief valve is built
into the torque converter to prevent excessively raising the oil pressure in the converter due to oil
viscosity rising when cold.
Pressure adjusted oil passes through pressure detecting valve, inching valve and directional valve,
and operates the forward or reverse hydraulic clutch.
The pressure detecting valve and built in accumulator provide a soft plugging when changing gears.
The pressure detecting valve allows the accumulator to absorb the small shocks of rapid pressure
build-up and quick release during gear changes. When full pressure builds up, the pressure
detecting valve shuts the accumulator off and allows it to empty so it is ready to function again
during gear change.
The inching control is actuated through the inching pedal. This permits the clutch to partially
disengage, so that engine rpm can be increased for lifting while travel speed remains low.
3-10
5. HYDRAULIC CLUTCH
1) STRUCTURE(Reverse and forward 1st)
Center line of
Hydraulic clutch
Center line 18
1
of engine
19
20
Clutch
22
23
24
25 15
26
Hypoid pinion
27
28
29 17
31 16
30
32
21
14
16
17
15
2
3
4
13 7
5
6
8
9
14 10
11
12
25
24
23
22
13
D153PT12
1 T/Plug 12 Spacer 23 Spring

2 Seal ring 13 Ring 24 Washer
3 Snap ring 14 Disc 25 Snap ring
4 Spacer 15 Plate 26 Gear
5 Spring 16 Piston 27 Needle bearing
6 Steel ball 17 Seal ring 28 Washer
7 Ball bearing 18 O-ring 29 Spacer
8 Spacer 19 Shaft 30 Spring
9 Washer 20 Rivet 31 Spacer
10 Bearing 21 Drum 32 Spacer
11 Gear 22 Seal ring
3-11
2) CLUTCH PACKS
The clutch packs have a driving side and a driven side for each gear selection, a total of two(1
forward, 1 reverse). One clutch pack assembly has two selections on the same shaft, forward and
reverse, and the clutches are back to back with a spur gear in the middle.
The forward reverse clutch pack is driven by the turbine shaft of the torque converter. The assembly
makes up the main part of the driving sides of the two clutch packs. This assembly is rotating at
turbine speed whenever the torque converter turbine is rotating, no matter what gear is selected,
including neutral.
Into each of these driven clutch pack bodies fits a hydraulic piston, and a set of alternating drive
plates(steel) and friction plates(fiber faced). The steel plates have teeth on the outer edge which
slide into the slots in the clutch pack body, and rotate with the clutch pack. Each of the fiber faced
plates have teeth on the inner edge which engage a spline on a driven gear. A return spring on the
shaft keeps the piston from engaging the clutch when there is no hydraulic pressure from the
control valve.
A driven gear(or output gear) slides over the clutch pack shaft and engages the teeth on the inside
edge of the friction plates.
Return spring Piston
Forward Reverse
Shaft
Friction plate
Drive plate
Forward/reverse clutch pack assembly
D255PT23
3-12
3) OPERATION
Forward Reverse
Reverse
(From control valve)
From T/M cooler
1
2
Seal ling 3
Forward
(From control valve)
4
D255PT24
When a gear is selected by the operator, the following happens.

1 The clutch pack shaft is being driven by the torque converter.
2 The spur gear and clutch pack body is attached to shaft and rotates with it.
3 The clutch piston is pressurized by transmission fluid from the control valve.
4 The pressurized piston compresses the drive plates and the friction plates, causing them to rotate
together.
5 The driven(or output) gear rotates with the clutch pack body and drives the forward shaft gear or
pinion spur gear, depending on gear selection.
There are three oil ports that enter the clutch pack shafts through the manifold caps. Two(A, B) are for
supplying transmission fluid to the clutch pistons. The third(C) is to supply lubrication to the gears and
clutch discs. Seal rings separate oil flow from manifold cap.
3-13
6. DRIVE AXLE
1) STRUCTURE
26
3 25
29
1 27
5
4 12
17
16
29
28 11
18
21
15
19 13
14
20 24
22 23
10
D255PT25
1 Housing 14 Nut 22 Oil seal

2 Cap 15 Nut 23 Bolt
3 Plug 16 Bearing 24 Spring washer
4 Plug 17 Oil seal 25 Brake assy(LH)
5 Gasket 18 Bearing 26 Brake assy(RH)
10 Shaft 19 Plate 27 Reamer bolt
11 Hub 20 Nut 28 Bolt
12 Brake drum 21 Bolt 29 Spring-washer
13 Bolt
2) OPERATION
Both sides of the housing are supported by the frame and the center is mounted on the
transmission case with bolts.
The mast is installed on the front of the drive axle housing through the trunnion. The final
deceleration and differential device built in the housing guarantee accurate rotation and smooth
operation. The power from the transmission is transferred through the hypoid pinion, hypoid gear,
differential case, the pinion of the differential device and the side gear to the drive axle shaft by the
side gear spline and to the hub and wheel mounted on the shaft by high tension bolts.
3-14
GROUP 2 TROUBLESHOOTING
Trouble symptom Probable cause Remedy

1. Excessive oil
temperature rise ·Improper oil level. ·Check oil level. Add or drain oil as
1) Torque converter necessary.
·Impeller interfering with surroundings. ·After draining oil from oil tank and tra-
nsmission, check and replace interfe-
ring parts.
·Stator and free wheel malfunctioning. ·Check enigne (stalling) speed.
If necessary, replace.
·Air sucked in. ·Check the inlet side joint or pipe.
If necessary, retighten joint or repla-
ce gasket.
·Water intruding into transmission ·Check drained oil.
case. If necessary, change oil.
·Bearing worn or seizing. ·Disassemble, inspect, repair or repla-
ce.
·Gauge malfunctioning. ·Check and, if necessary, replace.
2) Transmission ·Clutch dragging. ·Check to see whether or not machi-
ne moves even when transmission is
placed in neutral position. If so, repl-
ace clutch plate.
·Bearing worn or seized. ·Disassemble, check and replace.
2. Noise operation
1) Torque converter ·Cavitation produced. ·Change oil, replace parts leaking air.
·Flexible plate damaged. ·Listen to rotating sound at lowspeed
operation. If necessary, repacle flex-
ible plate.
·Bearing damaged or worn. ·Disassemble, check and replace.
·Gear damaged. ·Disassemble, check and replace.
·Impeller interfering with surroundings. ·Check impeller or check drained oil
for mixing of foreign matter.
If necessary, change oil.
·Bolt loosening. ·Disassemble and check. If necessa-
ry, retighten or repalce.
·Spline worn. ·Disassemble, check and replace.
·Noise gear pump operation. ·Disassemble, check and replace.
2) Transmission ·Dragging caused by seizing clutch. ·Check to see whether or not machine
moves even when transmission is in
neutral position. If so, replace clutch
·Bearing worn or seizing. plate.
·Gear damaged. ·Disassemble, check and replace.
·Bolt loosening. ·Disassemble, check and replace.
·Disassemble, check and retighten or
replace.
·Spline worn. ·Disassemble, check and replace.
3-15
3.Low output power
1) Torque converter ·Insufficient hydraulic pressure :
- Low oil level. - Check oil level and add oil.
- Air sucked in. - Check joints and pipes.
If necessary, retighten joint or repla-
ce packing.
- Oil filter clogging. - Check and replace.
- Oil pump worn. - Check oil pressure. If necessary rep-
(Low delivery flow) lace pump.
- Regulator valve coil spring fatigu- - Check spring tension. If necessary,
ed. replace.
- Control valve spool malfunctioning. - Disassemble, check and repair or re-
place.
- Piston or O-ring worn. - Disassemble, check measure and re-
place.
·Stator free wheel cam damaged. - Check stalling speed.
(Increased engine load will cause ex-
cessive drop of stalling speed.)
- Check oil temperature rise.
If any, replace free wheel.
2) Transmission ·Flexile plate deformed ·Replace flexible plate.
·Stator free wheel seizing. - Check temperature plate.
(No-load will cause temperature rise)
- Replace free wheel if a drop of start-
ing output is found.
·Impeller damaged for interfering with - Check drained oil for foreign matter.
the surroundings. If any, change oil.
·Use of poor quality of oil or arising of - Check and change oil.
air bubbles.
- Air sucked in from inlet side. - Check joints and pipes.
If necessary, retighten joint or replace
packing.
- Low torque converter oil pressure - Check oil pressure.
accelerates generation of air beb-
bles.
- Oil mixing with water. - Check drained oil and change oil.
- Inching rod out of adjustment. - Check and adjust.
·Clutch slipping
- Lowering of weight. - Check oil pressure.
- Piston ring or O-ring worn. - Disassemble, check, measure and
replace.
- Clutch piston damaged. - Disassemble, check and replace.
- Clutch plate seizing or dragging. - Check to see whether or not machine
moves even when transmission is in
neutral position. If so, replace.
3-16
4.Unusual oil pressure
1) Oil pressure is high ·Control valve malfunctioning. (1)Check for spool operation.
If necessary, replace valve.
(2)Check for clogging of small hole in
valve body. If necessary, clean or
repair.
·Cold weather. (high oil viscosity) ·When atmospheric temp is below fr-
eezing point
(when normal oil pressure is recover-
ed if heated to 60 ~ 80。C), change
oil.
·Use of improper oil. ·Check and change oil.
2) Oil pressure is low ·Gear pump malfunctioning(worn). ·Disassemble, check and replace.
·Oil leaks excessively :
(1)Control valve oil spring defective. ·Check spring tension (see spring sp-
ecification).
If necessary replace.
(2)Control valve spool defective. ·Disassemble, check, and repair or re-
place valve.
·Air sucked in. ·Check joints and pipes. If necessary,
retighten joint or replace packing.
·Low oil level. ·Check oil level and add oil.
·Oil filter clogging. ·Check and replace.
3) Transmission ·Oil leaks excessively. ·Disassemble, check (piston ring and
O-ring for wear and other defects),
and replace.
5.Power is not transmitted
1) Torque converter ·Clutch plate damaged. ·Check for damage by listening to ab-
normal sounds at a low converter sp-
eed and replace.
·Low oil level. ·Check oil level and add oil.
·Oil pump driving system faulty. ·Disassemble and check for wear of
pump gear, shaft and spline.
Replace defective parts.
·Shaft broken. ·Check and replace.
·Lack of oil pressure. ·Check oil pump gear for wear and for
oil suction force.
If necessary, replace pump.
2) Transmission ·Low oil level. ·Check oil level and add oil.
·Inching valve and link lever improper- ·Check measure and adjust.
ly positioned.
·Forward/reverse spool and link lever ·Check and adjust.
improperly positioned.
·Clutch fails to disengage :
(1)Clutch case piston ring defective. ·Disassemble, check and replace.
(2)Main shaft plug slipping out. ·Disassemble, check and repair or re-
place.
·Clutch seizing. ·Check to see whether or not machine
moves even then transmission is in
neutral position. If so, replace.
·Shaft broken off. ·Disassemble, check(main shaft, etc.),
and replace.
·Clutch drum damaged (spring groove). ·Disassemble, check and replace.
·Clutch snap ring broken. ·Disassemble, check and repair or re-
place.
3-17
5. Power is not transmitted ·Foreign matter intruding into oil pass- ·Disassemble, check and repair or
(Continue) age to clutch. replace.
·Shaft spline worn. ·Disassemble, check and replace.
6. Oil leakage ·Oil leaks from oil seal. ·Disassemble and check for wear of
(Transmission and torque seal lips and mating sliding surfaces
converter) (pump boss, coupling etc.)
Replace oil seal, pump boss, coupl-
ing, etc.
·Oil leaks from case joining surfaces. ·Check and retighten or replace pack-
ing.
·Oil leaks from joint or pipe. ·Check and repair or replace gasket.
·Oil leaks from drain plug. ·Check and retighten or gasket.
·Oil leaks from a crack. ·Check and replace cracked part.
3-18
GROUP 3 TESTS AND ADJUSTMENTS
1. INCHING PEDAL
m
150m
1) Depress inching pedal fully, and move gear
shift lever to FORWARD or REVERSE.
140~
Check that machine does not move even
when engine speed is increased slightly.
2) Adjust stopper bolt so that pedal height is
140~150mm (5.5~5.9in).
D255BS13
3) Adjust stopper bolt so that brake pedal

35~45mm
interconnects with inching pedal at a stroke
of 35~45mm. Inching pedal
m Brake pedal
150m
Inching pedal
140~
interconnection
Stopper bolt
D205BS12
3-19
2. HYDRAULIC PRESSURE
1) Block wheels of truck, and pull parking lever. Install oil pressure gauge at inlet of control valve.
2) Move direction control lever to FORWARD or REVERSE, depress accelerator pedal and run engine
at 1500rpm. Measure clutch pressure and torque converter pressure and check that they are within
specified range.
3. ENGINE STALL SPEED

Move direction control lever to FORWARD or REVERSES, and run engine at maximum speed.
Check that maximum engine speed is within specified range.
※ This check raises the temperature of the oil in the torque converter, so do not run this test for
a long period.
Model Stall speed
YANMAR 4TNE98-HYF(IDI) 1700rpm
4. DIFFERENTIAL
1) FITTING DIFFERENTIAL ASSEMBLY
(1) Install the differential assembly and fit
adjust screw gear(1).
Loctite
(2) Apply loctite in the hole of cap(2), and #271
temporarily tighten with bolt(3). 3 1
2) ADJUSTMENT OF BACKLASH
※ Tighten the adjust screw gear(1). 2
L15C3DF01
(1) To adjust the backlash, loosen one

adjustment screw gear 1 notch and 1 A
tighten the other screw gear 1 notch.
Gradually move the differential case in this
way, and watch the indicator of the dial
gauge to adjust to the correct value.
·Backlash between ring gear and pinion
gear : 0.15~0.23mm(0.006~0.009in).
(2) Turn the bevel gear to adjust screw
L15C3DF02
gear(1) at 4 places.
3-20
3) ADJUSTMENT OF THE SIDE BEARING
PRELOAD
Tighten adjust screw gear(1) uniformly at
20kgf·m(145lbf·ft)
L15C3DF03
4) ADJUSTING TOOTH CONTACT

Forward side m
(1) Coat the tooth face of the bevel pinion 6m 4in)
. 2
( 0
lightly with red lead(minimum). m
4m 6in)
(0.
1 Heel
(2) Rotate the bevel gear forward and
backward.
(3) Inspect the pattern left on the teeth.
Toe
%
· Tooth contact should be checked with no
70
~
40
load on the bevel pinion. The tooth
n)
i
39
0 m
contact pattern should cover about .2 0 m
0.
~
(0 ~1
5
D255TH01
40~75% of the length of the tooth, with
weak contact at both ends.
Reverse side
D255TH02
(4) If the result of the inspection shows that the correct tooth contact is not being obtained, adjust
again as follows.
(See next page for details)
Adjust shims at pinion shaft.
Adjust backlash of bevel gear.
Adjust backlash of bevel gear side bearing.
※ Tooth contact should be checked with no load on the bevel pinion. The tooth contact pattern
should cover about 40~75% of the length of the tooth, with weak contact at both ends.
※ The tooth contact should be correct on both the FORWARD and REVERCE side of the teeth,
however, if it is impossible to adjust both sides correctly, the FORWARD side must be correct.
3-21
5) INCORRECT TOOTH CONTACT
Heel
(1) Increase the shim thickness at the pinion
shaft to move the pinion in direction A.
Then move the bevel gear away from the
pinion gear in direction B.
Adjust the backlash again. B
A
Toe
L15C3TH03
(2) Reduce the shim thickness at the pinion

Then move the bevel gear closer to the A

Adjust the backlash again.
L15C3TH04
(3) Reduce the shim thickness at the pinion

A
Then move the bevel gear closer to the
L15C3TH05
(4) Increase the shim thickness at the pinion

Then move the bevel gear away from the
B
A
L15C3TH06
3-22
GROUP 4 DISASSEMBLY AND ASSEMBLY
1. TRANSMISSION
1) DISASSEMBLY
(1) Disassemble torque converter assembly
Drain the transmission fluid and disconn-
ect the torque converter assembly from the
engine and the transmission.
(2) Disassemble input side of torque converter

Remove the input plate bolts and the input
plate, input guide, and O-rings.
Tool(s) required : 12mm wrench.
L15C3TC01
L15C3TC02
(3) Extract torque converter

① Remove the turbine shaft snap ring.
Tool(s) required : Snap ring pliers
L15C3TC03
3-23
② Ease the torque converter out of the
housing so as not to damage the pump oil
seal.
L15C3TC04
(4) Extract pump

Remove the inner turbine shaft snap ring
and all bolts holding the pump.
Tool(s) required : 12mm socket wrench
L15C3TC05
(5) Extract turbine shaft

① Remove the two snap rings.
Tool(s) required : Snap ring pliers
L15C3TC06
② Extract the turbine shaft.
L15C3TC07
3-24
(6) Extract valves
① Remove the two plugs.
L15C3TC08
② Remove the springs and pistons.

Level the two sets-the springs especially-
so that they do not get confused.
L15C3TC09
(7) Disassemble oil pump

Remove the O-ring and philips screws
and disassemble the pump.
※ Limit disassembly to the minimum
amount required.
L15C3TC10
3-25
2) ASSEMBLY
The assembly procedure is the reverse of
the disassembly procedure above, but
requires additional care as noted below.
(1) Assembly oil pump
Return the gears and stator support to
their positions before disassembly.
Check the gear action. If the gears do not
rotate smoothly, disassemble the pump
and start over.
·Bolt tightening torque : 0.1kgf·m(0.72lbf·ft)
L15C3TC10
(2) Install valves

The valve assemblies are different, so make sure that they go back into the proper holes.
·Plug tightening torque : 5.0kgf·m(36.2lbf·ft)
(3) Install turbine shaft

Make sure that the sealing material is seal completely inside before inserting the shaft.
(4) Install pump

Lightly grease the pump casing with lithium grease (Shell albania Z or equivalent) to avoid
breaking or twisting O-ring when you insert it.
(5) Install torque convert
Fill the oil seal lip cavity one-half full with lithium grease or coat the surface with clean hydraulic
fluid to avoid damaging the oil seal and bushing when you insert the torque converter.
(6) Install input side of torque converter
Coat the O-ring with lithium grease before installing.
(7) Install torque converter assembly

Connect the torque converter assembly to the engine and the transmission.
※ After each step, check your work against the maintenance standards which appear after the
procedure.
※ Apply semidrying liquid gasket to the circumference of oil seals, but do not allow it to get on
the lips or the shaft’s sliding surface.
3-26
3) TORQUE CONVERTER ASSEMBLY DRAWING
D255TC12
L15C3TC13
3-27
4) CHECK AND INSPECTION
Turbine
Impeller Torque
converter
Input Stator
plate
C1
B
Gear pump
G
H, I
Turbine
shaft
Housing
Engine side
Transmission side
L15C3TC14
A3
A1
A1
E1
A2
E2
F
L15C3TC15
3-28
Unit : mm(in), kg(lb)
Criteria
No. Check item Remedy
Standard size Repair limit
Clearance between piston 0.015-0.025 0.065 Replace
A1 and housing hole (0.0006-0.001) (0.0025) piston
Free 89.9 87.3
length (3.54) (3.43)
Torque converter Installed 63 63
Torque A2 inlet relief valve length (2.48) (2.48)
spring
converter Installed 7.70 6.94
A load (16.98) (15.3)
input output
Free 122 120.4
valve length (4.80) (4.74)
Torque converter
output pressure Installed 103.5 103.5
A3 adjusting valve length (4.07) (4.07)
spring Installed 3.45 3.11
load (7.61) (2.36)
60
B Oil seal O.D - (2.36)
Torque converter Oil seal mating 59.952-60.000 59.852 Replace
C impeller valve C1 face outer dia (2.360-2.362) (2.356)
Clearance of abutment 0.1-0.3 1.0
E1 when housing is inserted (0.004-0.012) (0.04)
E Seal spring
2.47-2.49 2.27
E2 Ring with (0.097-0.098) (0.089)
2.56-2.60 2.7
F Turbine shaft(Seal ring groove width) (0.100-0.102) (0.106)
48.0-48.025 48.12
G Housing(Seal ring portion inner dia) (1.889-1.890) (1.894)
47.951-47.970 Clearance
H Impeller hub O.D (1.887-1.888) between hub
47.975-48.000 and bushing
I Pump bushing (1.889-1.890) 0.1(0.0039)
Corrected
15 14.85 by hard
J Pilot(Tip outer dia) YANMAR engine chrome
(0.59) (0.38)
plating
3-29
5) MAINTENANCE STANDARDS
(1) Hydraulic pressure
No Location Pressure (kgf/cm2) Cracking pressure (kgf/cm2)

1 Torque converter input 5~7 5
2 Torque converter output 2.2 ~ 4 2.2
※ Cracking pressure means the pressure at which the valve begins to open.
(2) Tightening torques

Tightening torque in
No Location Thread specifications kgf·m(lbf·ft)
Target Maximum
1 Input plate Small hex bolt M8×1.25×20 2.1(15.2) 2.7(19.5)
2 Pump Small hex bolt M8×1.25×40 2.1(15.2) 2.7(19.5)
3 Valves Plug M16×1.5 ×10 5.0(36) 6.5(47)
4 Cover Small hex bolt M8×1.25×12 0.98(7) 1.3(9)
Torque converter fluid
5 outlets Hex plug with hole PT 1/4 3.5(25.3) 4.4(31.8)
6 Pump assembly Small flathead screw M5×0.8×16 0.1(0.72) 0.3(2.2)

7 Blind plug Hex plug with hole PT3/4 5.8(42) 7.2(52.1)
3-30
2. TRANSMISSION
※ Keep all parts in order as disassembly
progresses. Take care to properly
identify each part and its order of
removal.
If necessary, keep notes and put
markings on parts using a non-
destructive marker such as a felt-tipped
pen.
1) DISASSEMBLY
(1) Differential, torque converter, control
valve
① Detach the differential from the torque
converter. Loctite
#271
3 1
2
L15C3DF01
② Remove the control valve.
D255TM01
(2) Cage
① Remove the cage.
(With holder at the pinion end).
D255TM02
3-31
(3) Pinion shaft
① Remove pinion shaft bolt(1).
② Fit a dolly block(copper rod) and tap the
pinion shaft with a hammer to remove.
D255TM03
(4) Seal ring cap

4
① Remove bolt(2) and fit the bolt to the 3
tapped hole.
Remove the seal ring cap.
※ Pull out the cap straight without
2
twisting it.
② Remove seal ring(3).
③ Remove snap ring(4).
D255TM04
(5) Clutch pack assembly

Remove front and rear clutch pack
assembly.
D255TM05
(6) Idler shaft assembly

① Remove bolt(9) and slide the shaft
assembly as shown in the drawing. Bearing
puller
② Remove the bearing and the shaft
assembly using a bearing puller.
9
D255TM06
3-32
(7) Disassembly of components of clutch pack assembly
※ The number shows the sequence of disassembly.
9
29
36
35
34
33
7 10 32
19
31
8 27 30
13 25
24
12 23
11
6 28
5
17
4
2 3
1
26
22
21
20
18
16
15
14
L15C3CL01
1 Sealing 13 Spring 25 Snap ring

2 Spring 14 Piston 26 Disc
3 Spacer 15 Sealing 27 Plate
4 Washer 16 Sealing 28 Ring
5 Gear 17 Needle bearing 29 Ball
6 Spacer 18 Shaft assembly 30 Washer
7 Ball 19 Needle bearing 31 Gear
8 Ring 20 Sealing 32 Washer
9 Plate 21 Sealing 33 Spacer
10 Disc 22 Piston 34 Spacer
11 Snap ring 23 Spring 35 Spring
12 Washer 24 Washer 36 Spacer
※ Spring under heavy compression. Carefully remove with press.
3-33
2) ASSEMBLY
※ Cleanliness is of extreme importance in the repair and overhaul of this assembly. Perform all
disassembly work in a clean area. Overhaul the transaxle only in a clean, dust-free location,
using clean tools and equipment. Dirt or grit will damage the highly-machined sufaces and
result in premature failure of components. Cleanliness of interior surfaces, orifices, etc. is
extremely important to the proper operation of the hydraulic circuit. The exterior surface of
the unit must be thoroughly cleaned of all dirt and foreign substances to prevent
contamination of the parts during overhaul. Protect all components from dust and dirt while
repairs are being made. Be sure the work area is kept clean.
(1) Assembly of components of the clutch

pack assembly.
Assembly is in the reverse order to
disassembly but pay attention to the
following.
① Piston ring Ball
Fit the piston ring.
Notch
L15C3TM07
② Ball, Spacer, Spring

Coat the ball with oil and then fix it to the
hole of the shaft match the notch of the
spacer with the ball and insert.
③ Spacer, Spring
Spacer Spacer
Spacer consists of two halves. Ball Piston spring Ball
Fix the spacer with a spring.
Spacer
Ball Spacer
Spring Spring
D255TM08
3-34
(2) Idler shaft assembly
① Prefit gear(1) in the case.
② Fit bearing(2) on the idler shaft and install
in the case. 2 3
③ Fix bearing(3) fix it with plate(4) and bolt

(5).
45
·Tightening torque : 2.8 ~ 3.5kgf·m
(20 ~25lbf·ft) 1
D255TM09
(3) Clutch pack assembly 2

① Fit bearing(1) in the case. 3 1
② Fit F-R clutch pack assembly.
4
③ Fit snap ring(2).
④ Fit seal ring(3).
⑤ Fit seal ring cap fix with bolt(5). 5
·Tightening torque : 10 ~ 12.5kgf·m
(72 ~90lbf·ft)
D255TM10
(4) Pinion shaft assembly

① Install pinion shaft assembly in the case.
② Fix with plate(1) and bolt(2).
③ Fix cage(3).
Cage(3)
1 2
D255TM11
(5) Differential, control valve

① Fit the differential to the case with cap(1) 5
and bolt(2). 6
3
※ Refer to adjustment of backlash after 4
attaching the differention.
2 1
② Fit control valve(3) and gasket(4) with
bolt(5).
·Tightening torque : 2.8 ~ 3.5kgf·m
(20 ~25lbf·ft)
D255TM12
3-35
3) TORQUEFLOW TRANSMISSION ASSEMBLY DRAWING
Loctite #271(Screw hold side)
Loctite #271(Screw hold side)
G2-L1(Lip portion)
(Loctite #271 : Screw hole side)
35 ~ 43.5 kgf . m(253 ~ 315 lbf . ft) Match the stamps on the
inner and outer rings
D255TM13
3-36
D G B E F A C
D
H
J1
A2 A1
E2, H2
B1
B2 E1, H1
C2
G1
I1
C1 F1
D2
D255TM14
3-37
Unit : mm(in)
Criteria
No Check item Remedy
3.13-3.27 2.9
A1 Thickness of drive plate (0.123-0.129) (0.114)
A Plate 2.6(0.102) Replace
A2 Thickness of driven plate 2.90-3.05 (Oil groove depth
(0.114-0.120) Min0.2)(0.008)
Clearance of abutment when 0.36-0.56
B1 piston is inserted (0.014-0.002) -
0.15-0.35 Replace
B Sealing B2 Depth of the side face oil groove (0.006-0.014) To be grooved at each
disassembly
2.60-2.65 2.8
(D1) Width of groove for insertion (0.102-0.104) (0.110)
40.025-40.050 40.2
C1 Sealing matching face I.D (1.576-1.577) (1.583)
C Piston Width of groove when sealing is 3.1-3.2 3.4
C2 inserted. (0.122-0.126) (0.134)
Width of the groove for inserting 2.60-2.65 2.8
D1 sealing. (0.102-0.104) (0.110)
D Drive shaft Width of the groove of inserting 2.60-2.65 2.8
D2 sealing. (0.102-0.104) (0.110)
Clearance of abutment when 0.2-0.4 2.77
E1 clutch case is inserted (0.008-0.157) (0.109)
2.97-2.99 1.0
E Sealing E2 Width (0.117-0.118) (0.039)
3.1-3.2 3.4
(C2) Width of groove for insertions (0.122-0.126) (0.134)
100-100.054 100.3
F Clutch case F1 Sealing matching face I.D (3.937-3.939) (3.949)
2.9-3.1 2.5 Replace
G Thrust G1 Thickness (0.114-0.122) (0.098)
Clearance of abutment when cap 0.05-0.25 0.65
H1 is inserted (0.002-0.010) (0.026)
2.47-2.49 2.25
H Sealing H2 Width (0.097-0.098) (0.089)
2.60-2.65 2.8
(D1) Width of groove for insertions (0.102-0.104) (0.110)
35.000-35.021 35.2
I Cap I1 Sealing matching face I.D (1.378-1.379) (2.552)
64.926-65.000 64.83
J Retainer J1 Oil seal maching face O.D (2.556-2.559) (1.386)
0.08-0.28
- Backlash (0.003-0.011) -
- Each gear 0.3-0.7
- Clearance of thrust (0.012-0.028) -
Replace with
a new part
- Gasket, O-ring, seals - - when
disassembly
and assembly
3-38
3. DIFFERENTIAL
1) STRUCTURE
TRANSMISSION
Loctite #271
12
11
6
5
7
35~43.5 kgf . m
(253~315 lbf . ft) 3 4
2 6
5
13 5~7.5 kgf . m 8 7
(36~54 lbf . ft) 8
Loctite #271(Hole side)
5 5
6
6
(Run out : Max, 0.1 with

dial guage reading) 9
10
16~20 kgf . m
(116~145 lbf . ft) 14
13
Loctite #271(Hole side)
11
Starting torque : 3.1~5.7 kgf . m 12
(22~41 lbf . ft)
Adjust with screw gear(12)
D255DF04
※ Ring gear and pinion must be replaced as one unit.

Do not replace one without the other.
1 Case 6 Washer 11 Taper bearing

2 Case 7 Differential pinion 12 Screw gear
3 Hexagon bolt 8 Bushing 13 Bolt
4 Spider 9 Bevel gear 14 Plate
5 Differential pinion 10 Bolt
3-39
2) DIFFERENTIAL ASSEMBLY DRAWING
Backlash : 0.10-0.18 mm
(0.004-0.007 in)
Runout is Max 0.1
Starting torque (1)

3.1-5.7 kgf . m
(22-41 lbf . ft)
Loctite#271(screw portion) Loctite#271(screw portion)

5-7.5 kgf . m
16-20 kgf . m
(36-54.4 lbf . ft)
(116-145 lbf . ft)
Loctite#271(screw hole side)

35-43.5 kgf . m
(253-315 lbf . ft)
D255DF05
3-40
C E
D B
D255DF07
Unit : mm(in)
Criteria
No Check item Remedy
Differential pinion gear and Scratches on the Replace (Replace bevel
A side gear - teeth gear and pinion)
24.959-24.980 24.75
B O.D of spider (0.983-0.984) (0.974)
25.0-25.1 25.2
C I.D of differential pinion gear (0.984-0.988) (0.992)
1.94-2.06 1.7
D Width of bushing (0.076-0.081) (0.067) Replace
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)
Gasket Replace with new parts
- O-ring - - when reassembling after
Seals disassembling.
3-41
4. DRIVE AXLE(DRY RYPE)
1) DISASSEMBLY AND ASSEMBLY
2
7
6
8
9
26
3 25
29
1 27
5
4 12
17
Loctite #1215
6~8 kgf . m 16
All face of flange
(43~58 lbf . ft)
29
28 11
18
Loctite #271
19
32.5~43.5 kgf . m
20 (235~315 lbf . ft)
21
15
13
Starting torque 14
0.6~1.5 kgf . m
(4.3~10.8 lbf . ft)
22
30~50 kgf . m
10 (217~362 lbf . ft)
24
23
10~13 kgf . m
(72~94 lbf . ft)
D255DA01
1 Housing 11 Hub 21 Bolt

2 Cap 12 Brake drum 22 Oil seal
3 Plug 13 Bolt 23 Bolt
4 Plug 14 Nut 24 Spring washer
5 Gasket 15 Nut 25 Brake assy(LH)
6 Dowel pin 16 Bearing 26 Brake assy(RH)
7 Gasket 17 Oil seal 27 Reamer bolt
8 Bolt 18 Bearing 28 Bolt
9 Spring washer 19 Plate 29 Spring washer
10 Shaft 20 Nut
3-42
2) ASSEMBLY OF DRIVE AXLE
6-8 kgf . m
(43-58 lbf . ft)
4
14
D
PC
Three Bond #1215

Loctite #271 (All face of flange)
Starting torque :
0.6-1.5 kgf . m
(4.3-10.8 lbf . ft)
10~13 kgf . m
(72-94 lbf . ft)
Loctite #271
30-50 kgf . m G2,L1
(217-362 lbf . ft)
Loctite #271
32.5-43.5 kgf . m
(235-315 lbf . ft)
G2,L1
Grease by 1/2-2/3 of space
capacity(On hub side)
G2,L1
D255DA02
3-43
3) INSTALLATION
Perform installation in the reverse order to
removal, paying attention to the following.
(1) Tightening torque converter case
mounting bolt. Mounting
bolt
·Tightening torque : 6.0-7.5kgf·m
(43-54lbf·ft)
D255TIN01
(2) Tightening flexible plate mounting bolt.

Flexible plate
·Tightening torque : 2.8-3.5kgf·m mounting bolt
(20-25lbf·ft)
D255TIN02
(3) Pedal assembly brake piping.

① Inching drawing
Refer to the drawing on the right.
② Adjustment of pedal
Refer to “Adjustment of pedal” T/M control
valve
33mm
Clearance : 0~0.5 mm
(0~0.02 in)
D255TIN03
(4) Mast
Cap mounting bolt.
·Tightening torque : 25-31.5kgf·m
(181-228lbf·ft)
3-44
Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1

Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-6
Group 3 Tests and Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-9
GROUP 1 STRUCTURE AND FUNCTION
1. OUTLINE
There are two brake systems, the foot brake system and the hand brake system.
In the foot brake system, oil pressure is generated in the master cylinder by treading on the brake
pedal. This pressure causes the wheel cylinder pistons to extend, expanding the brake shoes and
pressing them against the brake drums to attain braking force.
In the hand brake system, the brake shoes are expanded by operating the brake lever.
Force from the lever is transmitted to the brake shoes through the hand brake cables and a lever
arm in each wheel brake assembly.
The wheel brake is the duo-servo type. With force applied to both the primary and secondary
shoes, this type provides a large amount of brake force.
In addition, the brake equipped with automatic adjusters which constantly adjust the clearance
between the shoe and the drum, compensation for wear due to the shoe friction and thus keeping
the clearance constant.
2. SPECIFICATION
1) WHEEL BRAKE(DRY ONLY)
Item Specification
Type Front wheel, duo-servo & auto adjustment type

Brake shoe size 310×60mm
Wheel cylinder bore diameter 28.57mm
Master cylinder diameter 19.05mm
Free height 140~150mm
Pedal adjustment
Pedal play 10~15mm
Brake drum diameter Normal 310mm
Wheel cylinder installation torque 0.7~1.3kgf·m
Backing plate installation torque 15~20kgf·m
Brake oil Only use for brake fluid DOT3
2) PARKING BRAKE(DRY TYPE)
Item Specification
Type Toggle, internal expanding mechanical type

Parking lever stroke 214mm
Parking cable stroke 18~19mm
4-1
3. BRAKE PEDAL AND PIPING(DRY TYPE)
The brake system provides two systems, a foot brake and a parking brake.
In the foot brake system, the oil pressure which is generated in the master cylinder when the brake
pedal is depressed is transmitted to the wheel cylinders. The piston of the wheel cylinder presses
the brake shoes and then moves outward causing contact with the drums and braking force is
obtained. In the parking brake system, the force is transmitted to move the brake shoe through a
brake cable to activate the brake when the brake lever is operated.
The wheel brake is a dual servo type in which the actuating force is applied to both the primary and
secondary shoes. Even if the applied force is small, a large braking force will be obtained.
These brakes are equipped with self adjusters which continuously adjusts the brakes in small
increments in direct proportion to the wear of the linings.
Drive axle
Wheel brake
D255BS01
1 Brake pedal & bracket assy 3 Reservoir tank assy

2 Parking lever assy 4 Master cylinder
4-2
4. INCHING PEDAL AND LINKAGE(DRY TYPE)
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 are applied.
35~45mm
Brake pedal
Master cylinder 140~150mm
Inching spool
Transmission
control valve
D255BS02
4-3
5. WHEEL BRAKE(DRY ONLY)
1) STRUCTURE
The wheel brake assembly mounts to the flange on the drive axle housing casting and is basically
contained within the hub assembly.
The inside of the hub is machined and acts as the brake drum.
1
30 10 3 31 161713
27
A
28,29 21
F 22
23
B B
D D C C
19
E E
11 Section A-A
2
8
24 14 5 12 20 7
6
26 9
25
Section D-D Section C-C
Section F-F
15 18
Section B-B 4
Section E-E
D255BS03
1 Back plate assy(LH/RH) 12 Lever pawl(LH/RH) 22 Bleed screw-cap

2 Lined shoe assy 13 Stopper 23 Plug
3 Wheel cylinder assy 14 Spring 24 Lever(LH/RH)
4 Bolt-set 15 Retaining-ring 25 Pin
5 Adjuster assy(LH/RH) 16 Strut 26 Retaining-ring
6 Pin 17 Spring 27 Sleeve
7 Spring 18 Parking cable assy(LH/RH) 28 Bolt
8 Washer 19 Plug 29 Spring-washer
9 Bush 20 Spring 30 Shoe A
10 Plate 21 Bleed-screw 31 Shoe B
11 Lever actuator(LH/RH)
4-4
6. BRAKE MASTER CYLINDER(DRY TYPE)
1) STRUCTURE
7
3
6
5
16
20 12 11
21 19
17 18
14
22 15
13
1 10
9
8
4
D255BS04
1 Body 7 Spacer 13 Rod 18 Band bolt

2 Piston 8 Plate 14 Yoke 19 Band plate
3 Primary cup 9 Key wire 15 Nut 20 Band washer
4 Secondary cup 10 Boot 16 Nipple 21 Cap
5 Spring 11 Check valve 17 Band 22 Cap
6 Spring seat 12 Valve seat
2) DISASSEMBLY
(1) Remove the master cylinder boot(10) and remove the rod(13).
(2) Remove the key wire(9) and take out the plate(8), the piston(2), the piston primary cup(3), and
piston spring(5).
(3) Specification of master cylinder.
·Cylinder bore diameter : 19.05mm
·Piston stroke : 23.0mm
3) INSPECTION
(1) Clean and check these components.
※ Use isopropyl alcohol or brake fluid for washing the components. Do not use gasoline, kerosene or any
other mineral oils. When using alcohol, do not leave rubber parts in the liquid for more than 30 seconds.
(2) Inspect the inside wall of the master cylinder, and if any faults are found, replace the cylinder assembly.
(3) Replace the boot(10), the primary cup(3), piston(2), if deformation or any other defect is found.
4) ASSEMBLY
※ Prior to assembly make sure again of no contaminant of the components. Apply a thin coat of
brake oil to the components.
·Assembly is in opposite order to disassembly.
4-5
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 is depressed. Check also change in
operating force, and change in position of pedal when pedal is kept depressed.
2) WHEEL BRAKE
Compact wheel base chassis
(1) Measure lining at point with most wear, and check that lining thickness is at least 2.0mm(0.08in).
(2) Hold lining surface with screwdriver to prevent piston from coming out, depress brake pedal and
check movement of shoe.
(3) Remove brake shoe from anchor pin, and check for rust or wear.
When assembling, coat sliding parts with special brake grease.
3) BRAKE DRUM
(1) Measure inside diameter of drum, and check that it is within 310mm(12.2in).
4) BACKING PLATE
(1) Check visually for deformation or cracks.
Check particularly for deformation at outside circumference of plate and at mounting bolt.
(2) Coat mounting bolt with loctite and tighten : 15~20kgf·m(108~145lbf·ft).
5) BRAKING FORCE
(1) Select a dry, flat, paved surface and drive truck at maximum speed. When signal is given, stop
truck immediately and measure distance from point where signal was given to point where truck
stopped. (unloaded)
·Stopping distance : Within 5m(197in)
(2) Check that there is no pulling of steering wheel, pulling by brakes to one side or abnormal noise
when making emergency stops.
6) PARKING BRAKE(DRY TYPE)
2
(1) Operating force of parking lever is 20 - 30 1
kgf(44 - 66lbf).
(2) Check that parking brake can hold
machine in position when loaded on 15%
slope. If there is no slope available, travel
at low speed and check braking effect of
parking brake.
L15C3BS05
4-6
2. TROUBLESHOOTING
Problem cause Remedy

Insufficient braking force ·Hydraulic system leaks oil. ·Repair and add oil.
·Hydraulic system leaks air. ·Bleed air.
·Lining surface soiled with water or oil. ·Clean or replace.
·Lining surface roughened or in poor ·Repair by polishing or replace.
contact with drum.
·Lining worn. ·Replace.
·Brake valve or wheel cylinder mal- ·Repair or replace.
functioning.
·Hydraulic system clogged. ·Clean.
Brake acting unevenly. ·Tires unequally inflated. ·Adjust tire pressure.
(Machine is turned to one ·Brake out of adjustment. ·Adjust.
side during braking.) ·Lining surface soiled with water or oil. ·Clean or replace.
·Earth intruding into brake drum. ·Clean.
·Lining surface roughened. ·Repair by polishing or replace.
·Lining in poor contact with drum. ·Repair by polishing.
·Brake drum worn or damaged ·Repair or replace.
(distortion or rusting).
·Wheel cylinder malfunctioning. ·Repair or replace.
·Brake shoe poorly sliding. ·Adjust.
·Back plate mounting bolt loose. ·Retighten or replace.
·Back plate deformed. ·Replace.
·Wheel bearing out of adjustment. ·Adjust or replace.
Brake trailing. ·Pedal has no play. ·Adjust.
·Brake shoe poorly sliding. ·Adjust.
·Wheel cylinder mal-functioning. ·Repair or replace.
·Piston cup faulty. ·Replace.
·Return spring fatigued or bent. ·Replace.
·Parking brake fails to return or out of ·Repair or adjust.
adjustment.
·Brake valve return port clogged. ·Clean.
·Wheel bearing out of adjustment. ·Adjust or replace.
Brake chirps ·Brake trailing. ·See above. Brake trailing.
·Piston fails to return. ·Replace.
4-7
Problem cause Remedy
Brake squeaks ·Lining surface roughened. ·Repair by polishing or replace.
·Poor shoe to lining contact. ·Replace.
·Excessively large friction between ·Clean and apply brake grease.
shoe and back plate.
·Foreign matter on drum sliding surfa- ·Clean
ce.
·Drum sliding surface damaged or di- ·Replace.
storted.
·Brake shoe deformed or poorly insta- ·Replace or repair.
lled.
·Back plate mounting bolt loosening. ·Retighten.
·Worn anchor or other contact portion. ·Replace.
·Lining poor contact with drum. ·Repair or replace.
·Anti-rattle spring poorly installed. ·Repair or replace.
Brake rapping ·Drum sliding surface roughened. ·Repair by polishing or replace.
·Drum eccentric or excessively distort- ·Replace.
ed.
Large pedal stroke ·Brake out of adjustment. ·Adjust.
·Hydraulic line sucking air. ·Bleed air.
·Oil leaks from hydraulic line, or lack ·Check and repair or add oil.
of oil.
·Shoe tilting or does not return compl- ·Repair.
etely.
·Lining in poor contact with brake ·Repair.
drum.
Pedal dragging. ·Twisted push rod caused by improp- ·Adjust.
erly fitted brake valve.
·Brake valve seal faulty. ·Replace.
·Flow control valve orifice clogged. ·Clean or replace.
Abnormal noise ·Lining worn. ·Replace
·Poor shoe to lining contact. ·Replace.
·Excessively large friction between ·Clean and apply brake grease.
shoe and back plate.
·Foreign matter on drum sliding sur- ·Clean
face.
·Drum sliding surface damaged or ·Replace
distorted.
·Brake shoe deformed or poorly in- ·Replace or repair.
stalled.
·Back plate mounting bolt loosening. ·Retighten
·Worm anchor or other contact portion. ·Replace
·Lining in poor contact with drum. ·Repair or replace.
4-8
GROUP 3 TESTS AND ADJUSTMENTS
1. ADJUSTMENT OF WHEEL BRAKE(DRY ONLY)
Adjust with engine stopped.
1) Jack up truck. Extend adjustment screw by
clicking adjustment wheel teeth with a
Adjustment wheel Lever
screwdriver until wheel(mounted on brake
drum being adjusted) offers a light
resistance when turned by hand. Back
adjustment wheel by 25~30 teeth to shorten
length of adjustment screw.
※ When backing adjustment wheel, be sure Adjustment screw
to adequately raise adjustment lever to Brake shoe
extracting direction
keep it free from interference with
adjustment wheel. If lever is bent by
mistake, it loses proper function. L15C3BS06
2) After adjusting brake, drive machine for

about 500m, then check heat of brake drum
at 4 points to confirm that brakes are not
dragging.
3) After adjusting, confirm that brake stopping
distance is within standard range.
2. AIR BLEEDING OF BRAKE SYSTEM

1) Air bleeding should be performed by two
persons :
One rides on truck for depressing and
releasing brake pedal : the other person is
on the ground and removes cap from air
vent plug on wheel cylinder. Air vent
2) Block the front wheel securely and apply Brake drum plug
parking brake.
3) Start the engine.
4) Attach a vinyl tube to air vent plug and
immerse other end of tube into a vessel
filled with hydraulic oil. Lining
5) Loosen air vent plug by turning it 3/4 with a Hydraulic oil

wrench. Depress brake pedal to drain oil
mixed with air bubbles from plug hole.
6) Depress brake pedal until no air bubbles
come out of air vent plug hole.
7) After completion of air bleeding, securely
tighten air vent plug. Install cap on plug. L15C3BS07
4-9
3. ADJUSTMENT OF PEDAL(DRY TYPE)
1) BRAKE PEDAL
m
dal
(1) Pedal height from floor plate
150m
e pe
Adjust with stopper bolt.
140~
Brak
·Pedal height : 140~150mm(5.5~5.9in)
(2) Play
Adjust with rod of master cylinder
·Play : 10~15mm(0.4~0.6in)
(3) Micro switch for parking brake (if D255BS08
equipped)
① After assembling parking brake and
parking cable, put the parking brake lever
released.
② Loosen the nut for parking brake plate to (40
)
play up and down.
③ Move up the plate so that the stopper can Stopper
be contacted with the pin and then
reassemble nut.
·Micro switch stroke when parking
brake is applied : 2~3mm
L15C3BS09
2) INCHING PEDAL(DRY TYPE)

(1) Pedal height from floor plate Inching spool
Adjust with stopper bolt.
·Pedal height : 140~150mm(5.5~5.9in) Transmission
control valve
(2) Inching spool protrusion
Adjust with inching cable so that when the
inching pedal is fully returned, the protrus- Stroke 24mm
ion of spool from the end face of the 33mm
control valve is the specified valve.
·Protrusion : 33mm(1.3in) L15C3BS10
(3) Adjust bolt so that brake pedal interconn-

ects with inching pedal at inching pedal 35~45mm
stroke 35~45mm(1.4~1.8in).
m
dal
150m
e pe
140~
Brak
D255BS11
4-10
Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1

Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-10
Group 3 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-12
1. OUTLINE
MCV
1
2
T
P L
R
1 Steering unit
2 Steering cylinder
3 Steering wheel
4 Trail axle
To Hydraulic tank
D255SS01
The steering system for this machine is composed of steering wheel assembly(3), steering unit(1),
steering cylinder(2), trail axle(4) and pipings. The steering force given to the steering wheel enters
the steering unit through the steering column. The required oil flow is sensed by the function of the
control section of the unit, and pressurized oil delivered from the hydraulic pump is fed to the
steering cylinder. The force produced by the steering cylinder moves the knuckle of steering tires
through the intermediate link.
The axle body is unit structure having steering knuckles installed to its both ends by means of
kingpins. Hub and wheel are mounted through bearing to spindle of knuckle.
5-1
2. HYDRAULIC CIRCUIT
D255SS02
1 Hydraulic gear pump 5 Steering cylinder

2 Priority valve 8 Suction filter
4 Steering unit 12 Hydraulic tank
5-2
1) NEUTRAL
D255SS03
The steering wheel is not being operated so control spool(G) does not move.
The oil from hydraulic gear pump(1) enters port P of Priority valve(2) and the inlet pressure oil
moves the spool(D) to the left.
Oil flow into LS port to the hydraulic tank(12).
So, the pump flow is routed to the main control valve.
5-3
2) LEFT TURN
D255SS04
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) within the steering unit(4)
through the spool(D) of priority valve(2) and flows to the gerotor(H).
Oil flow from the gerotor(H) flows back into the spool(G) where it is directed out of the left work
port(L).
Oil returned from cylinder returns to hydraulic tank(12).
When the above operation is completed, the machine turns to the left.
5-4
3) RIGHT TURN
D255SS05
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) where it is directed out of the
right work port(R).
Oil returned from cylinder returns to hydraulic tank(12).
When the above operation is completed, the machine turns to the right.
5-5
3. STEERING UNIT
1) STRUCTURE
D255SS06
1 Dust seal 14 Bearing race 24-3 Spring seat

2 Retaining ring 15 Bore screw 24-4 Spring
3 Cap seal 16 Drive 24-5 Spool
4 Thrust bearing 17 End cap 24-6 Bushing
5 Ball 18 Gland bushing 25 Check valve
6 Pin 19 Plate 25-1 Guide
7 Spacer 20 Cap screw 25-2 Shim
8 Center spring 21 Housing 25-3 Spring
9 Washer 22 Spool 25-4 Washer
10 O-ring 23 Sleeve 26 Suction valve
11 Seal 24 Relief valve 26-1 Roll pin
12 Roller screw 24-1 Plug 26-2 Ball
13 Gerotor set 24-2 O-ring
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. TRAIL AXLE
1) STRUCTURE
12
12
32
16
17 3
15 33 30
13 31 30
14 18 31
2 4 34
1 35
28 38 40
29
6 36 39
5
8
7 15
17
16
34 2 19
20
38 4
35 8 37
7 23
11 21
40 10
36 9
39 22
24
25
26
27
D22SS07
1 Steering axle 15 Needle bearing 28 Shim

2 Knuckle 16 Plate plug 29 Shim
3 Intermediate link 17 Retaining ring 30 Special washer
4 Grease nipple 18 King pin 31 Split pin
5 Set screw 19 Hub bolt 32 Steer cylinder
6 Nut 20 Hub 33 Shim
7 Bolt 21 Taper roller bearing 34 Block
8 Nut 22 Taper roller bearing 35 Bushing
9 Bolt 23 Oil seal 36 Grease nipple
10 Spring washer 24 Washer 37 Hub nut
11 Plain washer 25 Slotted nut 38 Shim
12 Link pin 26 Split pin 39 Bolt
13 Inner race bush 27 Hub cap 40 Hardened washer
14 Thrust bearing
5-8
2) TIGHTENING TORQUE AND SPECIFICATION
77 53.
.8 71
4
Stroke 95
Apply loctite #277

49.5~66.5 kgf . m(358~481 lbf . ft)
Greasing Fill 1/2 to 2/3 of the space

in the hub with lithium
grease
Bearing end should
be leveled with boss end
Fix with split pin
SECTION A-A D255SS09
Center pin support

Type Unit
single shaft
Structure of knuckle - Elliott type
Toe-in degree 0
Camber degree 1
Caster degree 0
King pin angle degree 0
Max steering angle of
wheels(Inside/Outside) degree 77.84 / 53.71
Tread mm(in) 1003(39.5)
5-9
Check item Checking procedure
Steering wheel · Set rear wheels facing straight forward, then turn steering wheel to left and right.
30-60mm Measure range of steering wheel movement before rear wheel starts to move.
(1.2-2.4 in)
Range should be 30~60mm at rim of steering wheel. If play is too large, adjust
at gear box.
Test steering wheel play with engine at idling.
Knuckle · Check knuckle visually or use crack detection method. If the knuckle is bent, the
tire wear is uneven, so check tire wear.
Steering axle · Put camber gauge in contact with hub and measure camber.
If camber is not within 1±0.5°; rear axle is bent.
· Ask assistant to drive machine at minimum turning radius.
· Fit bar and a piece of chalk at outside edge of counterweight to mark line of
turning radius.
· If minimum turning radius is not within±100mm (±4in)of specified value, adjust
turning angle stopper bolt.
Min turning radius(Outside)
HDF20-5 2273mm(90in)
HDF25-5 2325mm(92in)
HDF30-5 2380mm(94in)
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.
※ Oil pressure : 91.8kgf/cm2 (90bar)
2. TROUBLESHOOTING
Problem Cause Remedy
Steering wheel drags. ·Low oil pressure. ·Check lockout. Repair.
·Bearing faulty. ·Clean or replace.
·Spring spool faulty. ·Clean or replace.
·Reaction plunger faulty. ·Replace.
·Ball-and-screw assembly faulty. ·Clean or replace.
·Sector shaft adjusting screw excessi- ·Adjust.
vely tight.
·Gears poorly meshing. ·Check and correct meshing.
·Flow divider coil spring fatigued. ·Replace.
Steering wheel fails to return ·Bearing faulty. ·Clean or replace.
smoothly. ·Reaction plunger faulty. ·Replace.
·Ball-and-screw assy faulty ·Clean or replace.
·Gears poorly meshing. ·Check and correct meshing.
5-10
Steering wheel turns unstea- ·Lockout loosening. ·Retighten.
dily. ·Metal spring deteriorated. ·Replace.
Steering system makes abn- ·Gear backlash out of adjustment. ·Adjust.
ormal sound or vibration. ·Lockout loosening. ·Retighten.
·Air in oil circuit. ·Bleed air.
Abnormal sound heard when Valve
steering wheel is turned fully ·Faulty. (Valve fails to open.) ·Adjust valve set pressure and check
for specified oil pressure.
Piping
·Pipe(from pump to power steering ·Repair or replace.
cylinder) dented or clogged.
Piping makes abnormal Oil pump
sounds. ·Lack of oil. ·Add oil.
·Oil inlet pipe sucks air. ·Repair.
·Insufficient air bleeding. ·Bleed air completely.
Valve or valve unit makes Oil pump
abnormal sounds. ·Oil inlet pipe sucks air. ·Repair or replace.
Valve
·Faulty. (Unbalance oil pressure) ·Adjust valve set pressure and check
specified oil pressure.
Piping
·Pipe(from pump to power steering) ·Repair or replace.
dented or clogged.
·Insufficient air bleeding. ·Bleed air completely.
Insufficient or variable oil flow. ·Flow control valve orifice clogged. ·Clean
Insufficient or variable dischar- Piping
ge pressure. ·Pipe(from tank to pipe) dented or ·Repair or replace.
clogged.
Steering cylinder head ·Packing foreign materal. ·Replace
leakage (Piston rod) ·Piston rod damage. ·Grind surface with oil stone.
·Rod seal damage and distortion. ·Replace
·Chrome gilding damage. ·Grind
Steering cylinder head thread ·O-ring damage. ·Replace
(A little bit leak is no problem)
Welding leakage ·Cylinder tube damage. ·Tube replace.
Rod ·Tube inside damage. ·Grind surface with oil store.
·Piston seal damage and distortion ·Replace
Piston rod bushing inner ·Bushing wear. ·Replace
diameter excessive gap
5-11
1. STEERING UNIT
1) STRUCTURE
D255SS06
1 Dust seal 14 Bearing race 24-3 Spring seat

2 Retaining ring 15 Bore screw 24-4 Spring
3 Cap seal 16 Drive 24-5 Spool
4 Thrust bearing 17 End cap 24-6 Bushing
5 Ball 18 Gland bushing 25 Check valve
6 Pin 19 Plate 25-1 Guide
7 Spacer 20 Cap screw 25-2 Shim
8 Center spring 21 Housing 25-3 Spring
9 Washer 22 Spool 25-4 Washer
10 O-ring 23 Sleeve 26 Suction valve
11 Seal 24 Relief valve 26-1 Roll pin
12 Roller screw 24-1 Plug 26-2 Ball
13 Gerotor set 24-2 O-ring
5-12
2) TOOLS
(1) Holding tool.
5-69(1)
(2) Assembly tool for O-ring and kin-ring.
5-69(2)
(3) Assembly tool for lip seal.
5-69(3)
(4) Assembly tool for cardan shaft.
5-69(4)
5-13
(5) Assembly tool for dust seal.
5-70(1)
(6) Torque wrench 0~7.1kgf·m

(0~54.4lbf·ft)
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 [kgf·m(lbf·ft)]

L 3/4 UNF - 16 13 (94)
R 3/4 UNF - 16 13 (94)
T 3/4 UNF - 16 13 (94)
P 3/4 UNF - 16 13 (94)
Mounting bolt M10×1.5 5.0 ±1.0 (36±7.2)
5-14
4) DISASSEMBLY
(1) Disassemble steering column from
steering unit and place the steering unit in
the holding tool.
Screw out the screws in the end cover(6-
off plus one special screw).
5-72(1)
(2) Remove the end cover, sideways.
5-72(2)
(3) Lift the gearwheel set(With spacer if fitted)

off the unit.
Take out the two O-rings.
5-72(3)
(4) Remove cardan shaft.
5-72(4)
5-15
(5) Remove distributor plate.
5-73(1)
(6) Screw out the threaded bush over the

check valve.
5-73(2)
(7) Remove O-ring.
5-73(3)
(8) Shake out the check valve ball and suction

valve pins and balls.
※ On some pins in which there are two
springs.
D353SE09
5-16
(9) Take care to keep the cross pin in the
sleeve and spool horizontal. The pin can
be seen through the open end of the
spool. Press the spool inwards and the
sleeve, ring, bearing races and thrust
bearing will be pushed out of the housing
together.
5-73(4)
(10) Take ring, bearing races and thrust

bearing from sleeve and spool. The outer
(Thin) bearing race can sometimes "stick"
in the housing, therefore check that it has
come out.
5-74(1)
(11) Press out the cross pin. Use the special

screw from the end cover.
5-74(2)
※ A small mark has been made with a

pumice stone on both spool and sleeve
close to one of the slots for the neutral
position springs(See drawing).
If the mark is not visible, remember to
leave a mark of your own on sleeve and
spool before the neutral position
springs are disassembled.
5-74(3)
5-17
(12) Carefully press the spool out of the sleeve.
5-74(4)
(13) Press the neutral position springs out of

their slots in the spool.
5-75(1)
(14) Remove dust seal and O-ring.
5-75(2)
Disassembling the pressure relief valve

(15) Screw out the plug using an 8mm hexagon
socket spanner.
Remove seal washers.
D353SE10
5-18
(16) Unscrew the setting screw using an 8mm
hexagon socket spanner.
D353SE11
(17) Shake out spring and piston. The valve

seat is bonded into the housing and cannot
be removed.
D353SE12
(18) The pressure relief valve is now disassem-

bled.
D353SE13
5-19
5) ASSEMBLY
(1) Assemble spool and sleeve.
※ 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 5-76(1)
holes opposite each other so that parts
of the holes in the sleeve are visible
through the slots in the spool.
(2) Place the two flat neutral position springs

in the slot.
Place the curved springs between the flat
ones and press them into place (see
assembly pattern).
5-76(2)
(3) Line up the spring set.
5-76(4)
(4) Guide the spool into the sleeve. Make

sure that spool and sleeve are placed
correctly in relation to each other.
5-77(1)
5-20
(5) Press the springs together and push the
neutral position springs into place in the
sleeve.
5-77(2)
(6) Line up the springs and center them.
5-77(3)
(7) Guide the ring down over the sleeve.

※ The ring should be able to rotate free of
the springs.
5-77(4)
(8) Fit the cross pin into the spool / sleeve.
5-78(1)
5-21
(9) Fit bearing races and needle bearing as
shown on below drawing.
5-78(2)
※ Assembly pattern for standard bearings

1
1 Outer bearing race 2
2 Thrust bearing 3
3 Inner bearing race
4 Spool
5 Sleeve 4
5
5-78(3)
Installation instruction for O-ring

(10) Turn the steering unit until the bore is
horizontal. Guide the outer part of the
assembly tool into the bore for the spool /
sleeve.
5-78(4)
5-22
(11) Grease O-ring with hydraulic oil and place
them on the tool.
5-79(1)
5-79(2)
(12) Hold the outer part of the assembly tool in

the bottom of the steering unit housing
and guide the inner part of the tool right to
the bottom.
5-79(3)
(13) Press and turn the O-ring into position in

the housing.
5-79(4)
5-23
(14) Draw the inner and outer parts of the
assembly tool out of the steering unit bore,
leaving the guide from the inner part in the
bore.
5-80(1)
Installation instructions for lip seal

(15) Lubricate the lip seal with hydraulic oil and
place it on the assembly tool.
5-80(2)
5-80(3)
(16) Guide the assembly tool right to the

bottom.
5-80(4)
5-24
(17) Press and turn the lip seal into place in the
housing.
5-81(1)
(18) With a light turning movement, guide the

spool and sleeve into the bore.
※ Fit the spool set holding the cross pin
horizontal.
5-81(2)
(19) The spool set will push out the assembly

tool guide. The O-ring are now in position.
5-81(3)
(20) Turn the steering unit until the bore is

vertical again. Put the check valve ball
into the hole indicated by the arrow.
5-81(4)
5-25
(21) Screw the threaded bush lightly into the
check valve bore. The top of the bush
must lie just below the surface of the
housing.
5-82(1)
(22) Grease the O-ring with mineral oil approx.

viscosity 500 cSt at 20°
C.
5-82(2)
(23) Place the distributor plate so that the

channel holes match the holes in the
housing.
5-82(3)
(24) Guide the cardan shaft down into the bore

so that the slot is parallel with the
connection flange.
5-82(4)
5-26
(25) Place the cardan shaft as shown - so that
it is held in position by the mounting fork.
5-83(1)
(26) Grease the two O-rings with mineral oil

approx. viscosity 500 cSt at 20° C and
place them in the two grooves in the gear
rim. Fit the gearwheel and rim on the
cardan shaft.
5-83(2)
(27) Important
Fit the gearwheel(Rotor) and cardan shaft
so that a tooth base in the rotor is
positioned in relation to the shaft slot as
shown.
Turn the gear rim so that the seven
through holes match the holes in the
housing.
5-83(3)
(28) Fit the spacer, if any.
5-83(4)
5-27
(29) Place the end cover in position.
5-84(1)
(30) Fit the special screw with washer and

place it in the hole shown.
5-84(2)
(31) Fit the six screws with washers and insert

them. Cross-tighten all the screws and
the rolled pin.
·Tightening torque : 3.0 ± 0.6kgf·m
(21.7 ± 4.3lbf·ft)
5-84(3)
(32) Place the dust seal ring in the housing.
5-84(4)
5-28
(33) Fit the dust seal ring in the housing.
5-85(1)
(34) Press the plastic plugs into the connection

ports.
※ Do not use a hammer!
5-85(2)
5-29
2. STEERING CYLINDER
1) STRUCTURE
8
12 7
6
5
2 4
10
12 11
1
9
10
4
5
6
7
8
D255SS11
1 Tube assembly 5 Rod seal 9 O-ring

2 Rod 6 Back up ring 10 O-ring
3 Gland 7 Dust wiper 11 Piston seal
4 DU bushing 8 Snap ring 12 Pin bush
5-30
2) DISASSEMBLY
※ Before disassembling steering cylinder, release oil in the cylinder first.
(1) Put wooden blocks against the cylinder tube, then hold in a vice.
(2) Remove the gland 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. If there are some damage, replace with new parts.
3) CHECK AND INSPECTION mm(in)

Criteria
Check item Remedy
Clearance between 0.064~0.137 0.180 Replace
piston & cylinder tube (0.0025~0.0054) (0.0070) piston seal
cylinder rod & bushing (0.0009~0.0044) (0.0049) bushing
Seals, O-ring Damage Replace
Cylinder rod Dents Replace
Cylinder tube Biting Replace
4) ASSEMBLY
(1) Install a new piston seal the groove on the piston.
※ Be careful not to scratch the seal too much
during installation or it will not seat properly.
D353SE27
(2) Install the rod seal to the position in the gland

applying a slight coat with grease prior to install.
D353SE28
5-31
(3) Install the dust wiper to the gland using a special
installing tool. Coat the dust wiper with grease
slightly before installing.
(4) Set a special tool the cylinder, gland assembly
into the cylinder tube.
D353SE29
(5) Using a hook spanner, install the gland

assembly, and tighten it with torque 60±6kgf·m
(434±43lbf·ft).
D353SE30
(6) After the gland assembly was installed to the

cylinder tube, calk at the tube end into the groove
on the gland to prevent screw loosening.
※ If it need calking again, never using previous
calking position.
D353SE31
(7) Move the piston rod back and forth several times for the full distance of its stroke. This helps to
seat the ring and seals before applying full hydraulic pressure to the cylinder.
(8) Install cylinder into trail axle.
(9) While idling the engine with the rear wheels off the ground, operate the steering wheel left and
right alternately.
※ Then, repeat the above operation at gradually increasing engine rpm. This releases air
from the system and completes preparation for operation.
(10) Stop the engine, lower the floating rear wheels, and check pump joints for oil leaks and looseness
and retighten, them as required.
5-32
3. TRAIL AXLE
1) STRUCTURE
※ Do not remove the stopper bolt unless necessary.
12
12
32
16
17 3
15 33 30
13 31 30
14 18 31
2 4 34
1 35
28 38 40
29
6 36 39
5
8
7 15
17
16
34 2 19
20
38 4
35 8 37
7 23
11 21
40 10
36 9
39 22
24
25
26
27
D22SS07
1 Steering axle 15 Needle bearing 28 Shim

2 Knuckle 16 Plate plug 29 Shim
3 Intermediate link 17 Retaining ring 30 Special washer
4 Grease nipple 18 King pin 31 Split pin
5 Set screw 19 Hub bolt 32 Steer cylinder
6 Nut 20 Hub 33 Shim
7 Bolt 21 Taper roller bearing 34 Block
8 Nut 22 Taper roller bearing 35 Bushing
9 Bolt 23 Oil seal 36 Grease nipple
10 Spring washer 24 Washer 37 Hub nut
11 Plain washer 25 Slotted nut 38 Shim
12 Link pin 26 Split pin 39 Bolt
13 Inner race bush 27 Hub cap 40 Hardened washer
14 Thrust bearing
5-33
C B A
D255SS12
mm(in)
Criteria
No. Check item Remedy
A Diameter of king pin 45(1.77) 44.8(1.76) Replace
B Vertical play of knuckle - 0.2(0.008) Adjust with shims
C Diameter of center pin 50(1.96) 49.5(1.94) Replace
- Rear axle, hub, knuckle, bearing ·Damage, wear Replace
·Seizure, abnormal noise, defective rotation
5-34
3) DISASSEMBLY
※ Servicing work on the knuckle part can be Tire
carried out without removing the axle assy from
chassis.
The work can be done by jacking up the Taper roller bearing
Washer
balance weight part of the truck.
Split pin
(1) Loosen the castle nut and take off the steering Slotted nut
wheel tire. Hub cap
D255SS13
(2) Remove hub cap.

(3) Pull out split pin and remove low slotted nut and
Wheel cap
plain washer. Split pin
(4) Using the puller, take off the wheel hub together Slotted nut
with the bearing. Hub
Be very careful because just before the hub

comes off, tapered roller bearing will fall out.
(5) After wheel hub is removed take off the inner
race of bearing.
(6) Pull out oil seal.
※ Don't use same oil seal twice.
Knuckle
Oil seal
Taper roller
bearing
Washer
D255SS14
(7) Repeat the same procedure for the other side.

Moreover, when disassembling is completed,
part the slotted nut in the knuckle to protect the
threaded portion.
5-35
(8) Loosen set screw(5) and nut(6).
(9) Pry out the retaining ring(17) and needle 16
bearing(15). 13 17
12 15
(10) Push out the king pin(18) without damaging the 14
knuckle(2). 18
(11) Remove the split pin(31) and the link pin(12). 2

1
Then, remove the knuckle(2). 28 30
29
6 31
※ Repeat the same procedure for the other 5
side.
8
7 15
17
16
D255SS15
4) ASSEMBLY
※ In reassembling, have all parts washed, grease
applied to lubricating parts, and all expendable
items such as oil seal and spring washers
replaced by new ones. 12
Perform the disassembly in reverse order.
3
(1) Tighten the set screw(5) of king pin. 18
33
30
※ There is a notch in the middle of the king 5
31
pin(18), make sure that this notch is on the
set screw side.
2
(2) Do not hammer to drive in needle bearing(15)
4
because it will break. 23
21
Always use drive-in tool. Be sure that the fixed
ring of the bearing is placed in position facing the
knuckle.
20
(3) Wheel hub
① Mount oil seal(23) and inner race of tapered
roller bearing(21) on the knuckle(2). The
bearing should be well greased before
assembling.
② Install the outer race of the bearing(22) in the
wheel center and assemble to the knuckle. 22
24
③ Tighten with slotted nut(25) and locked with split 25
26
pin (26). In locking with split pin, locate the hole 27
for the split pin by turning the nut back 1/6 of a
turn. Adjust the preload of bearing.
④ Mount the wheel cap(27). Bearing should be D255SS16
well greased before assembling.
5-36
Group 1 Structure and Function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1

Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-17
Group 3 Disassembly and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-21
1. HYDRAULIC CIRCUIT
D255HS01
1 Hydraulic gear pump 7 Tilt cylinder

2 Priority valve 8 Suction filter
3 Main control valve 9 Return filter
4 Steering unit 10 Down control valve
5 Steering cylinder 11 Down safety valve
6 Lift cylinder 12 Hydraulic tank
6-1
1) WHEN THE LIFT CONTROL LEVER IS IN THE LIFT POSITION
6 7
11
10 1A 2B 2A 3B 3A 4B 4A
15.0MPa
LIFT
TILT AUX1 AUX2
20.0MPa
3
P T
Steering system
LS CF EF
2
P
E/G 1
Return line
9
8
12
D255HS02
When the lift control lever is pulled back, the spool on the first block moves to lift position.
The oil from hydraulic gear pump(1) flows into main control valve(3) and then goes to the large
chamber of lift cylinder(6) by pushing the load check valve of the spool.
The oil from the small chamber of lift cylinder(6) returns to hydraulic oil tank(12) at the same time.
When this happens, the fork goes up.
6-2
2) WHEN THE LIFT CONTROL LEVER IS IN THE LOWER POSITION
6 7
11
10 1A 2B 2A 3B 3A 4B 4A
15.0MPa
LIFT
TILT AUX1 AUX2
20.0MPa
3
P T
Steering system
LS CF EF
2
P
E/G 1
Return line
9
8
12
L15C3HS03
When the lift control lever is pushed forward, the spool on the first block moves to lower position.
The work port(1A) and the small and the large chamber of lift cylinder are connected to the return
passage, so the fork will be lowered due to its own weight.
6-3
3) WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION
6 7
11
10 1A 2B 2A 3B 3A 4B 4A
15.0MPa
LIFT
TILT AUX1 AUX2
20.0MPa
3
T
Steering system
LS CF EF
2
P
E/G 1
Return line
9
8
12
D255HS04
When the tilt control lever is pushed forward, the spool on the second block is moved to tilt forward
position.
The oil from hydraulic gear pump(1) flows into main control valve(3) and then goes to the large
chamber of tilt cylinder(7) by pushing the load check valve of the spool.
The oil at the small chamber of tilt cylinder(7) returns to hydraulic tank(12) at the same time.
When this happens, the mast tilt forward.
6-4
4) WHEN THE TILT CONTROL LEVER IS IN THE BACKWARD POSITION
6 7
11
10 1A 2B 2A 3B 3A 4B 4A
15.0MPa
LIFT
TILT AUX1 AUX2
20.0MPa
3
P T
Steering system
LS CF EF
2
P
E/G 1
Return line
9
8
12
D255HS05
When the tilt control lever is pulled back, the spool on the second block is moved to tilt backward
position.
The oil from hydraulic gear pump(1) flows into main control valve(3) and then goes to the small
chamber of tilt cylinder(7) by pushing the load check valve of the spool.
The oil at the large chamber of tilt cylinder(7) returns to hydraulic tank(12) at the same time.
When this happens, the mast tilts backward.
6-5
2. HYDRAULIC GEAR PUMP
1) STRUCTURE
D255HS06
1 Housing 6 Oil seal 11 Side plate 2

2 Body 7 Idle gear 12 Bushing
3 Rear cover 8 Pin 13 Bolt
4 Snap ring 9 O-ring 14 Copper washer
5 Drive gear 10 Side plate 1
2) OPERATION
This pump comprises of a rear cover, a body, a housing, bushings and a mounting flange bolted
together. The gear journals are supported by bushings(12) to give high volumetric and mechanical
efficiencies.
6-6
3. MAIN CONTROL VALVE
1) STRUCTURE (4- Spool)
ANTI-STALL ORIFICE
1.2(TILT BLOCK ONLY)
F F G 16
A3 B 2 C D H 23
20 24 6
E
7 4 AUX2 AUX1 TILT LIFT
1 H 31
21 22 SECTION J-J
VIEW F-F
27
26
25
T T
5
12 E
28
F F G D
A B C SECTION H-H
VIEW G-G
13 14
15
17
29 8 9 10 19
18
33
Port name Size
34
32 Inlet port 1-1/16-12UNF-2B
6 Outlet port 1-1/16-12UNF-2B
SECTION T-T
11
SECTION E-E
D255HS07
1 Lift block assy 13 Relief piston 24 O-ring, retainer

2 Tilt block assy 14 Nut 25 Plug
3 Aux1 block assy 15 Relief plug 26 Steel ball
4 Aux2 block assy 16 O-ring 27 Load sensor spring
5 Plug 17 Relief spring 28 Load sensor spring
6 Plug 18 Pilot poppet 29 O-ring
7 Long bolt 19 Plug 30 O-ring
8 Hydrostat plug 20 O-ring 31 Side plate
9 O-ring 21 O-ring 32 Seat
10 Hydrostat spring 22 O-ring 33 Seat
11 Hydrostat sleeve 23 O-ring 34 Piston
12 O-ring
6-7
2) INLET SECTION OPERATION
(1) Structure and description
Relief valve piston 13 14

15
17 9
29 8 10
18
33
Relief valve piston 34
32
11
D255HS071
8 Hydrostat plug 15 Relief plug

9 O-ring 17 Relief spring
10 Hydrostat spring 18 Pilot poppet
11 Hydrostat sleeve 29 O-ring
13 Relief piston 32 Seat
14 Nut 33 Seat
6-8
(2) Operation
Secondary relief valve
To neutral passage
P
15.0MPa To aux block
System relief valve
T
20.0MPa
P To neutral passage
1
To load check valve
D255HS072
Oil flows from P(pump) port to reservoir(T) by pushing hydrostat spool(1).

Before the center bypass line closed, hydrostat spool is keep opening, so pump port(P) and tank
port(T) are always connected in operation to minimize heat generation.
6-9
3) LIFT SECTION OPERATION
(1) Lift position
1A
Load check valve
D255HS08
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 and flow into lift cylinder port(1A).
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.
6-10
(2) Lower position
1A
Load check valve

D255HS09
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 (1A)→T.
In lift lower position the fork drops due to its own weight.
6-11
4) TILT SECTION OPERATION
(1) Tilt forward position
2B 2A
Tilt lock spool
Load check valve

D255HS10
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 and flow into tilt cylinder port(2B).
The pump pressure reaches proportionally the load of cylinders and fine control finished by closing
the neutral passage.
The return oil from cylinder port(2A) flows into the tank through the hole of the tilt lock spool.
6-12
(2) Tilt backward position
2B 2A
Tilt lock spool
Load check valve
D255HS11
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 and flows into tilt cylinder port(2A).
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(2B) flows into the tank via the low pressure passage.
6-13
5) MAIN RELIEF VALVE
(1) Pressure setting
A good pressure gauge must be installed Relief plug Seat
in the line which is in communication with
Lock nut
the work port relief. A load must be
applied in a manner to reach the set
pressure of the relief unit. Adjust bar
Procedure Relief spring

① Loosen lock nut. O-ring Pilot poppet
② Set adjusting bar to desired pressure
setting. T
③ Tighten lock nut.
Main relief valve : 200 bar
④ Retest in similar manner as above.
P
D255HS12
(2) Operation
Pressurized oil over the relief pressure Pilot poppet
pushes pilot poppet and flows to tank
passage, therefore the system pressure
keeps under the adjusted relief pressure.
HP
Relief spring T
D255HS13
6-14
4. LIFT CYLINDER
D255HS18
1 Tube assembly 6 Wear ring 11 O-ring

2 Rod 7 Retaining ring 12 Guide
3 Piston 8 Gland 13 DU bushing
4 Piston seal 9 Dust wiper 14 Spacer
5 Back up ring 10 Rod seal 15 O-ring
5. TILT CYLINDER
2
18 17 16 19,20,21 9 10 15 11,12 13,14 8 1 3 4 6 5
7
D255HS19
1 Tube assembly 8 Rod cover 15 O-ring

2 Rod 9 Dust wiper 16 Rod eye
3 Piston 10 Du bushing 17 Bushing
4 Piston seal 11 Rod seal 18 Grease nipple
5 Wear ring 12 Back up ring 19 Hexagon bolt
6 O-ring 13 O-ring 20 Spring washer
7 Hexagon nut 14 Back up ring 21 Hexagon nut
6-15
6. FREE LIFT CYLINDER
D255HS20
1 Tube assembly 6 Check valve 11 Dust wiper

2 Rod 7 Back up ring 12 Snap ring
3 Piston 8 Set screw 13 O-ring
4 Piston seal 9 Gland 14 Back up ring
5 Wear ring 10 Rod seal
6-16
1) CHECK ITEM
(1) Check visually for deformation, cracks or
Within 8mm(0.31in)
damage of rod.
(2) Load maximum load, set mast vertical and
(after 2min)
raise 1m from ground. Wait for 2 minutes
and measure hydraulic drift(amount forks
move down and amount mast tilts
forward). D255HS21
·H Hydraulic drift
- Down(Downward movement of forks)
: Within 8mm(0.31in)
- Forward(Extension of tilt cylinder) Within 4mm(0.16in)
: Within 4mm(0.16in) (after 2min)
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)
Standard Under 0.6 (0.02)
D255HS22
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).
Normal
Line filter uses paper element, so replace
periodically(every 6 months or 1200
hours) L15C3HS23
3) CONTROL VALVE
(1) Raise forks to maximum height and
measure oil pressure.
Check that oil pressure is 200kgf/cm2.
(2845psi)
6-17
2. TROUBLESHOOTING
1) SYSTEM
Large fork lowering speed. ·Seal inside control valve defective. ·Replace spool or valve body.
·Oil leaks from joint or hose. ·Replace.
·Seal inside cylinder defective. ·Replace packing.
Large spontaneous tilt of ·Tilting backward : Check valve defec- ·Clean or replace.
mast. tive.
·Tilting forward : tilt lock valve defect- ·Clean or replace.
ive.
·Seal inside cylinder defective. ·Replace seal.
Slow fork lifting or slow mast ·Lack of hydraulic oil. ·Add oil.
tilting. ·Hydraulic oil mixed with air. ·Bleed air.
·Excessive restriction of oil flow on ·Clean filter.
pump suction side.
·Relief valve fails to keep specified ·Adjust relief valve.
pressure.
·Poor sealing inside cylinder. ·Replace packing.
·High hydraulic oil viscosity. ·Change to SAE10W, class CF engine
oil.
·Mast fails to move smoothly. ·Adjust roll to rail clearance.
·Oil leaks from lift control valve spool. ·Replace spool or valve body.
·Oil leaks from tilt control valve spool. ·Replace spool or valve body.
Hydraulic system makes ·Excessive restriction of oil flow pump ·Clean filter.
abnormal sounds. suction side.
·Gear or bearing in hydraulic pump ·Replace gear or bearing.
defective.
Control valve lever is locked ·Foreign matter jammed between sp- ·Clean.
ool and valve body.
·Valve body defective. ·Tighten body mounting bolts uniform-
ly.
High oil temperature. ·Lack of hydraulic oil. ·Add oil.
·High oil viscosity. ·Change to SAE10W, class CF engine
oil.
·Oil filter clogged. ·Clean filter.
6-18
2) HYDRAULIC GEAR PUMP

Pump does not develop full ·System relief valve set too low or ·Check system relief valve for proper
pressure. leaking. setting.
·Oil viscosity too low. ·Change to proper viscosity oil.
·Pump is worn out. ·Repair or replace pump.
Pump will not pump oil. ·Reservoir low or empty. ·Fill reservoir to proper level.
·Suction strainer clogged. ·Clean suction strainer.
Noisy pump caused by ·Oil too thick. ·Change to proper viscosity.
cavitation. ·Oil filter plugged. ·Clean filters.
·Suction line plugged or too small. ·Clean line and check for proper size.
Oil heating. ·Oil supply low. ·Fill reservoir to proper level.
·Contaminated oil. ·Drain reservoir and refill with clean oil.
·Setting of relief valve too high or too ·Set to correct pressure.
low.
·Oil viscosity too low. ·Drain reservoir and fill with proper
viscosity.
Foaming oil. ·Low oil level. ·Fill reservoir to proper level.
·Air leaking into suction line. ·Tighten fittings, check condition of
line.
·Wrong kind of oil. ·Drain reservoir, fill with non-foaming
oil.
Shaft seal leakage. ·Worn shaft seal. ·Replace shaft seal.
·Worn shaft in seal area. ·Replace drive shaft and seal.
3) MAIN RELIEF VALVE

Can’t get pressure ·Poppet D, E or K stuck open or ·Check for foreign matter between
contamination under seat. poppets D, E or K and their mating
parts. Parts must slide freely.
Erratic pressure ·Pilot poppet seat damaged. ·Replace the relief valve.
·Clean and remove surface
marks for free movement.
Pressure setting not correct ·Normal wear. Lock nut & adjust ·See page 6-15 for How to set
screw loose. pressure on work main relief.
Leaks ·Damaged seats. ·Replace the relief valve.
·Worn O-rings. ·Install seal and spring kit.
·Parts sticking due to contamination. ·Disassemble and clean.
6-19
4) LIFT CYLINDER

Oil leaks out from gland ·Foreign matters on packing. ·Replace packing.
through rod. ·Unallowable score on rod. ·Smooth rod surface with an oil stone.
·Unusual distortion of dust seal. ·Replace dust seal.
·Chrome plating is striped. ·Replace rod.
Oil leaks out from cylinder ·O-ring damaged. ·Replace O-ring.
gland thread.
Rod spontaneously retract. ·Scores on inner surface of tube. ·Smooth rod surface with an oil stone.
·Unallowable score on the inner ·Replace cylinder tube.
suface of tube.
·Foreign matters in piston seal. ·Replace piston seal.
Wear(clearance between ·Excessive clearance between ·Replace wear ring.
cylinder tube and wear ring) cylinder tube and wear ring.
Abnormal noise is produced ·Insufficient lubrication of anchor pin or ·Lubricate or replace.
during tilting operation. worn bushing and pin.
·Bent tilt cylinder rod. ·Replace.
6-20
1. HYDRAULIC GEAR PUMP
※ Tools required
·Metric socket set
·Internal snap ring pliers
·Shaft seal sleeve
·Torque wrench
(1) It is very important to work in a clean work
area when repairing hydraulic products.
Plug ports and wash exterior of pump with
a proper cleaning solvent before continu-
ing.
(2) Remove port plugs and drain oil from
pump.
(3) Use a permanent marker pen to mark a
line across the mounting flange, gear
housing and end cover. This will assure
proper reassembly and rotation of pump.
(4) Remove key from drive shaft if applicable.
PUMP 01
(5) Clamp mounting flange in a protected jaw

vise with pump shaft facing down.
(6) Loosen the four metric hexagon head
bolts.
(7) Remove pump from vise and place on
clean work bench, remove the four hexagon
head bolts and spacers applicable.
PUMP 02
6-21
(8) Lift and remove end cover.
PUMP 03
(9) Carefully remove gear housing and place

on work bench. Make sure the rear
bearing block remains on the drive and
idler shafts.
PUMP 04
(10) Remove rear bearing block from drive and

idler shafts.
PUMP 05
(11) Remove idler shaft from bearing block.
PUMP 06
6-22
(12) Remove drive shaft from mounting flange.
There is no need to protect the shaft seal
as it will be replaced as a new item.
PUMP 07
(13) Remove the front bearing block.
PUMP 08
(14) Turn mounting flange over, with shaft seal

up, and remove the retaining ring with
proper snap ring pliers.
PUMP 09
(15) Remove the oil seal from mounting flange,

be careful not to mar or scratch the seal
bore.
(16) Remove the dowel pins from the gear
housing. Do not lose pins.
PUMP 10
6-23
(17) Remove seals from both bearing blocks
and discard.
PUMP 11
2) INSPECT PARTS FOR WEAR

(1) Clean and dry all parts thoroughly prior to
inspection. It is not necessary to inspect
the seals as they will be replaced as new
items.
(2) Check drive shaft spline for twisted or
broken teeth, check keyed drive shaft for
broken or chipped keyway. No marks or
grooves on shaft in seal area, some
discoloration of shaft is allowable.
(3) Inspect both the drive gear shaft and idler
gear shafts at the bearing points and seal
area for rough surfaces and excessive
wear.
PUMP 12
(4) Inspect gear face for scoring or excessive

wear. If the face edge of gear teeth are
sharp, they will mill into the bearing blocks.
If wear has occurred, the parts are
unusable.
PUMP 13
6-24
(5) Inspect bearing blocks for excessive wear
or scoring on the surfaces which are in
contact with the gears. Also inspect the
bearings for excessive wear or scoring.
(6) Inspect the area inside the gear housing.
It is normal for the surface inside the gear
housing to show a clean "wipe" on the
inside surface on the intake side. There
should not be excessive wear or deep
scratches and gouges. PUMP 14
※ General information
It is important that the relationship of the
mounting flange, bearing blocks and gear
housing is correct. Failure to properly
assemble this pump will result with little or
no flow at rated pressure.
※ This pump is not bi-rotational.
6-25
3) ASSEMBLY
※ New seals should be installed upon
reassembly of pump.
(1) Install new shaft seal in mounting flange
with part number side facing outboard.
Press the seal into the seal bore until the
seal reaches the bottom of the bore.
Uniform pressure must be used to prevent
misalignment or damage to the seal.
PUMP 15
(2) Install retaining ring in groove in seal bore

of mounting flange.
PUMP 16
(3) Place front and back bearing blocks on a

clean surface with the E-seal grooves
facing up. Apply a light coating of
petroleum jelly in the grooves. Also coat
the E-seal and backup with the petroleum
jelly, this will help keep the seals in place
during assembly.
PUMP 17
(4) Place the E-seals, flat side outward, into

the grooves in both bearing blocks. Follow
by carefully placing the backup ring, flat
side outward, in the groove made by the
E-seal and the groove in the bearing
block.
(5) Place mounting flange, with shaft seal
side down, on a clean flat surface.
(6) Apply a light coating of petroleum jelly to
PUMP 18
the exposed face of the front bearing
block.
6-26
(7) Insert the drive end of the drive shaft
through the bearing block with the seal
side down, and the open side of the E-
seal pointing to the intake side of the
pump.
(8) Install the seal sleeve over the drive shaft
and carefully slide the drive shaft through
the shaft seal. Remove the seal sleeve
from shaft.
PUMP 19
(9) Install the idler gear shaft in the remaining

position in the bearing block. Apply a light
coat of clean oil to the face of the drive
and idler gears.
PUMP 20
(10) Pick up the rear bearing block, with seal

side up and with open end of the E-seal
facing the intake side of the pump, place
over the drive and idler gear shafts.
(11) Install two dowel pins in the holes in the
mounting flange or two long dowel pins
through gear housing if pump is a multiple
section pump.
PUMP 21
(12) To install the O-rings in the gear housing,

apply a light coating of petroleum jelly in
the grooves on both sides of the gear
housing.
Also coat the new O-ring and install them
in the grooves.
PUMP 22
6-27
(13) Gently slide the gear housing over the rear
bearing block assembly, slide housing
down until the housing engages the dowel
pins. Press firmly in place with hands, do
not force or use any tool.
Check to make sure the intake port in the
housing in on the same side as the open
end of the E-seal and that the marked
lines on the mounting flange and gear
housing are in alignment. PUMP 23
(14) The surface of the rear bearing block

should be slightly below the face of the
gear housing. If the bearing block sits
higher then the rear face of the gear
housing then the E-seal or O-ring have
shifted out of the groove. If this is the
case, remove the gear housing and check
for proper seal installation.
(15) Install the two remaining dowel pins in the

rear of the gear housing and place the
end cover over the back of the pump.
PUMP 24
(16) Install the four spacers and hexagon head

bolts through the bolt holes in the end
cover, hand tighten.
PUMP 25
6-28
(17) Place mounting flange of the pump back
in the protected jawed vise and alternately
torque the bolts.
·Tighten torque : 3.0~4.0kgf·m
(22~29lbf·ft)
(18) Remove pump from vise.
(19) Place a small amount of clean oil in the
inlet of the pump and rotate the drive shaft
away from the inlet one revolution. If the
PUMP 26
drive shaft binds, disassemble the pump
and check for assembly problems, then
reassemble the pump.
6-29
2. MAIN CONTROL VALVE
1) DISASSEMBLY
※ All hydraulic components are
manufactured to a high precision.
Consequently before disassembling or
assembling, it is essential to select an
especially clean place.
In handling a control valve, pay full
attention to prevent dust, sand, etc.
from entering into it.
D255CV24
(1) Loosen socket bolts from the valve and

then remove seal plate and dust wiper.
D255CV23
(2) Remove seal plate, dust wiper and O-ring

in order from the opposite side of return
cap.
D255CV22
(3) Loosen socket bolt fixing the return cap

from the return spring side of spool
assembly.
D255CV21
6-30
(4) Pull out spool assembly from the block.
D255CV20
(5) Using a jig, vise the spool assembly.

Remove spring seat, spring, seal, plate,
dust wiper and O-ring from the spool
assembly.
D255CV19
(6) Loosen blind plugs.
D255CV18
(7) Loosen blind plugs.
D255CV17
6-31
(8) Loosen plugs.
D255CV16
(9) Loosen hydrostat plug, spring and sleeve

from the inlet block.
※ When disassembling sleeve, use a
forceful magnet.
D255CV15
(10) Remove secondary relief valve.
D255CV14
(11) Remove spring and relief assembly.
D255CV13
6-32
(12) Remove pilot poppet.
D255CV12
(13) Remove relief valve assembly and then

disassemble relief assembly, relief spring,
pilot poppet in order from the relief valve
assembly.
D255CV11
(14) When removing C-ring, as the picture,

using a thin and soft tool, push up the C-
ring out of block.
D255CV10
(15) Remove another C-rings.

※ Check the C-ring’s cut side faces to
block’s center line.
D255CV09
6-33
(16) Remove adjust plug from the block.
D255CV08
(17) C-ring and adjuster assembly and

disassembly tool.
D255CV06
(18) For easy reassembly, check out the

direction of adjuster.
D255CV07
(19) For easy reassembly, check out the

direction of adjuster.
D255CV05
6-34
(20) Remove spring.
D255CV04
(21) Remove poppet.
D255CV03
(22) Procedure from (14) to (21) is load check

valve disassembly.
Remove O-ring and back up ring from
adjust plug.
D255CV02
(23) Separate inlet block, mid block and outlet

block each other by loosening the long
socket bolts from the block assembly.
D255CV01
6-35
2) ASSEMBLY
(1) With socket bolts fasten inlet block, mid
block and outlet block into one block.
·Tightening torque : 5.0kgf·m(36.2lbf·ft)
D255CV01
(2) Assemble load check valve in the order of

poppet, spring, adjuster, adjust plug and
C-ring.
D255CV02
(3) Install poppet into load check valve hole.
D255CV03
(4) Install spring into load check valve hole.
D255CV04
6-36
(5) Install adjuster into load check valve hole.
D255CV05
(6) A tool for disassembly and assembly of C-

ring or adjuster.
When assembling adjuster, push one of
two adjuster wings into the groove of block
and then the other in a same method.
D255CV06
(7) Assemble adjuster with attention of the

direction of wings.
D255CV07
(8) Assemble adjuster plug into load check

valve hole.
D255CV08
6-37
(9) Install C-ring into load check valve hole so
that cut side can face the center line of the
block.
D255CV09
(10) Assemble relief valve assembly.
D255CV11
(11) Install pilot poppet into relief valve hole.
D255CV12
(12) Install spring and relief assembly into relief

valve hole.
D255CV13
6-38
(13) Install secondary relief valve.
D255CV14
(14) Assemble hydrostat assembly in the order

of hydrostat sleeve, spring and plug.
※ Check the direction of sleeve.
※ Use a forceful magnet to pull out the
sleeve.
D255CV15
(15) Install plug.

D255CV16
(16) Install blind plug.
D255CV17
6-39
(17) Using a jig, vise a spool assembly.
Assemble in the order of O-ring, dust
wiper, seal plate, spring seat, and plug of
each spool.
D255CV19
(18) Install spool assembly into the block

assembly.
D255CV20
(19) Cover the return cap onto the return

spring side of spool assembly and then
tighten the socket bolt as following torque.
·Tightening torque : 1.2kgf·m
D255CV21
(20) On the opposite side of the return cap,

install O-ring, dust wiper and seal plate to
the spool in order.
D255CV22
6-40
(21) After assembling seal plate tighten socket
bolt as following torque.
·Install dust wiper so as lip side to face
outside.
D255CV23
(22) This is complete assembly procedure.
D255CV24
6-41
3. LIFT CYLINDER
1) STRUCTURE
C P
8
10
6 C P
11
3 Down control valve
13
5
12 4
A B
14
A B
1
Down safety valve

2
· I.D×O.D×Stroke : 50×58×1630mm
(2.0×2.3×64.2 in)
15 · Rod O.D : 40mm (1.6 in)
7
D255HS24
1 Tube assy 6 Wear ring 11 O-ring

2 Rod assy 7 Retaining ring 12 Guide
3 Piston 8 Gland 13 Du bushing
4 Piston seal 9 Dust wiper 14 Spacer
5 Back up ring 10 Rod seal 15 O-ring
6-42
2) DISASSEMBLY
(1) Hold the cylinder tube in a vice, loosen the Guide
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. L15C3HS25

Check item Standard size Repair limit Remedy

cylinder rod & bushing (0.003~0.011) (0.020) bushing
piston ring & tube (0.002~0.012) (0.020) piston ring
4) ASSEMBLY
(1) Soak the piston ring in hydraulic oil at a
temperature of 40 to 50。 C, expand the
inside diameter and assemble on the
piston. Install a piston seal.
Bend the edge of the guide and rotate it to
install the guide completely.
L15C3HS26
6-43
4. TILT CYLINDER
1) STRUCTURE
15
8
21
20
18 19
16
17
7
6
5
4
3
14
· I.D×O.D×Stroke : 75×86×138mm
13
11 (3.0×3.4×5.4 in)
12 · Rod O.D : 35mm (1.4 in)
10
D255HS27
1 Tube assy 8 Rod cover 15 O-ring

2 Rod 9 Dust wiper 16 Eye
3 Piston 10 DU bushing 17 Bushing
4 Piston seal 11 Rod seal 18 Grease nipple
5 Wear ring 12 Back up ring 19 Hexagon bolt
6 O-ring 13 O-ring 20 Spring washer
7 Nylon nut 14 Back up ring 21 Hexagon nut
6-44
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 D255HS28
threaded part of the rod and be careful not
to damage the dust seal and rod seal
inside cylinder head.

Check item Standard size Repair limit Remedy
Clearance between 0.072~0.288 0.5

Replace bushing
cylinder rod & 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)
6-45
Group 1 Component Location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1

Group 2 Electrical Circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2
Group 3 Component Specification - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Group 4 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-12
GROUP 1 COMPONENT LOCATION
15
1
5
2
14
13
7
TEMP
C
WATER
METER
HOUR
2
0 0
0 0
E FUEL
12
11
10
9
8
D255EL01
1 Flasher lamp 6 Back buzzer 11 Relay

2 Work lamp 7 Operating panel 12 Fuse box
3 Combination switch 8 Flasher relay 13 Switch assembly
4 Horn assembly 9 Detector 14 Warning buzzer
5 Combination lamp 10 Start switch 15 Battery
7-1
GROUP 2 ELECTRICAL CIRCUIT
D255EL02
7-2
OPSS (Operator Presence Sensing System)
REAR WORK OPTION

103 FUEL BACK AIR FUEL WATER
BEACON
FRONT HEAD FRONT HEAD OPERATING PANEL SENDOR BUZZER CLEARNER SEPARATOR
104 LAMP
COMBI LH LAMP COMBI RH LAMP
CL-23
OPTION
10,15(12V)
EARTH
105
CL-7
3
2,18
Pa
1
2
E
E
C
C
R T
R T
+
RB
RB
START KEY S/W
CN-65
CD-38
B
CD-10
B
CD-2
R
B
CL-24
CL-25
HOUR METER
WR
1
2
3
1
2
CL-3
CL-4
B
WATER TEMP GAUGE
12 11 10 9 8 7 6 5 4 3 2 1 B BR R1 R2 C ACC
FUEL EMPTY LAMP

HT
15A
15A
10A
10A
10A
10A
10A
10A
10A
AIR FILTER LAMP

10A
10A
10A
T/M OIL TEMP LP

CHARGE LAMP
FUEL GAUGE
GLOW LAMP
ILLUMINATION
WORK LAMP
ENG OIL PS LP
OFF
HEAD LAMP
TURN LP RH
TURN LP LH
OPERATING PANEL
253
257
REAR WORK LAMP
SEPARATOR
000
213
000
000
ON
000
208
209
GN
QGS & SAFETY IG
FUEL STOP SOL.
ST
1
WARNING RELAY
12V
000
292
-
LAMP SWITCH
202
000
5
BUZZER
TURN LAMP
STOP LAMP
F-R SWITCH
START SIG.
LEVEL
OPTION B+
OPTION IG
Br
W
R
L
3
HORN
CN-36
3
1
14
17
19
11
12
20
13
16
7
1
9
8
4
2
204
201
000
222
204
201
000
222
POWER
CN-56
8
2
6
7
4
CN-26
CR-35
CN-48
CN-58
CS-2
10
11
12
13
14
15
16
17
18
19
20
1
2
3
4
5
6
7
8
9
2
4
1
3
1
2
4
2
3
3
5
1
4
2
6
7
8
CN-18
207
218
291
290
206
254
223
205
216
217
215
227
CN-4
CN-5
1 2
2
4
1
3
3
CL-16
104
103
105
226
1 ST RW
293
223
223
000
256
293
201
000
201
257
252
210
255
224
205
203
204
251
208
205
256
253
000
222
202
251
000
000
253
209
224
205
256
257
000
290
2 CL RB
204
3 TN R
203
201
000
222
204
201
000
222
213
4 BK LW
HEATER 5
000
M 4 CN-19 6 B GN
722
3 3 R/COMBI RH
5A
721
0.7? 2 2
000
1 1 CL-15
226
CN-46 1 ST RW
201
2 CL RB
203
3 TN R
WASHER 213
BK LW
4
M 000
1 5
706 000
2 6 B GN
CN-22 R/COMBI LH
DIODE
000
1
706
2 SEAT SWITCH CL-21
201 WG
DO-2 000
000 B
1
CASSETTE RADIO 2
301
000
LICENCE LAMP
ILL- 1 CS-73 OPTION
N.C 2
712
S.R- 3
710 CN-17
S.L- 4 CD-9
291 291
N.C 5 1
290 290 293 WATER TEMP S/W
AT ANT 6 2
201 201 201 CN-1
ILL+ 7 3
000 000 201 201
N.C 8 4 1
713 202 202
S.R+ 9 2
290 203 203
ACC 10 3
291 204 204
B+ 11 4
711 206 206 226
S.L+ 12 5 1
207 207 207 BRAKE SW
N.C 13 6 2
000 208 208
GND 14 7 CD-4
209 209
CN-27 TRAVEL 8
CUT RELAY 210 210
9
303 211 211 CN-79
87a 10
RH SPEAKER 86 30
302 212 212 254 FUEL SHUT
85 11 OFF SOL.
712 213 213
2 87 12
713 216 292 292
1 86 13
85 87 87a
000 255 CD-18
CN-24 30 14 Pa E/OIL
CR-50 PS. S/W
LH SPEAKER
710 CN-2
2
711 251 251
1 1 CD-8
252 252 252 C WATER TMEP
CN-23 2
OPS UNIT 253 253 SENSOR
3
ROOM LAMP 216 254 254
IGN 1 4
290 301 255 255
2 SEAT S/W 2 5
000 213 256 256 256 T/M OIL
1 REV S/W 3 6 TEMP
212 257 257
CL-1 FWD S/W 4 7 CD-29
302 293 293
TRAVEL CUT 5 8
301 301
RELAY 2 6 9
000 303 303
GND 7 10
CN-11
OPS-LAMP 8 11
3
5
1
4
2
305 102
BUZZER - 9 12 GLOW PLUG
BRAKE S/W 10 CN-80
290
000
706
721
722
HEATER SWITCH RELAY 3 11

103 103
10
10 BATT + 12
9 000
9 PARK'G S/W 13
7 8 14 CN-74
5 4
7
251
1 L
1 CN-55
00
721 G
0
206
00
0
6
8
6 5
721 225
2 I
3 ~
2 290 3 P
U
4 103
B+
3 OPS
I 0
722 BUZZER
2 EARTH CN95B CN95A
722 305 101 103
1 1 2 2
216
CS-6 2 1 1
CN-113 FUSIBLE LINK

WIPER SWITCH
000
9 10 10
705
9 107 CN-45
704
3 8 M
8
7
705
100 M
6 6
1 100
5 B+
I
4
0,
706 START MOTOR

3
0 I
2
290
1
CS-3
211
206
000
210
102
101
211
206
225
000
20R
103
107
WIPER MOTOR OPTION
CR-24
CR-23
2
2
1
1
1
4
5
4
5
2
6
3
3
E S2
CN-122
CN-123
2 M 1 705
212
212
213
213
303
303
303
304
304
304
1 20B 20B
000
2
290
S1 3
4 704 BATTERY
QGS CONTROLLER
1
1
1
2
SAFETY RELAY
2
4
B MASTER SW
3 12V
CN-21
DO-1
000 FOWARD SOL. 4
1 REVERSE SOL.
705
2
204
203
219
000
215
201
221
221
220
216
212
213
DIODE
000
294
290
290
294
292
220
220
204
203
000
295
223
223
295
202
218
219
220
221
212
213
211
000
000
217
222
215
227
CS-11
CS-12
5
6
7
8
9
2
5
1
3
4
2
3
4
CR-11
CN-25
CS-23
CS-21
CS-41
10
2
1
8
5
4
1
6
2
9
3
10
13
11
12
10
10
2
6
7
8
9
1
4
3
5
4
5
4
1
6
2
9
3
2-TRH
4-FWD
4-HO
1-TLH
5-REV
8-Hi
7-Lo
6-ILL
11
10
3
4
5
5
10
10
6
5
12
13
NEUTRAL
6
>
HORN
2
7
E
7
8
2
1
10
9
7
7
8
8
2
1
3-HO
3-C
L
9-C HAZARD SWITCH REAR WORK LAMP

5-C BEACON LAMP S/W
1
HEAD
COMBI SWITCH OPTION OPTION
GEAR SELECTOR FLASHER UNIT/RELAY OPTION
D255EL021
7-3
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+)] Fusible link[CN-95B(1→2)] QGS controller[CR-24(2)]
Fusible link[CN-95A(1→2)] Safety relay[CR-23(1)]
Alternator[CN-74(B+)]
I/conn[CN-3]
I/conn[CS-2(3)] Start switch OFF
Fuse box[CN-36] Fuse box(No. 12) I/conn[CN-1(6)] Brake switch[CD-4(2→1)]
Rear combi switch[CL-16(1)]
Rear combi switch[CL-15(1)]
Fuse box(No. 11) I/conn[CN-17(1)]
Fuse box(No. 10) Horn[CN-25(1)] Combi switch[CS-12(3)]
2) CHECK POINT
Engine Key switch Check point Voltage
① - GND (Battery(+))
② - GND (Fusible link)
OFF OFF 10 ~ 13V
③ - GND (Fuse No.12)
④ - GND (Start key)
7-3
POWER CIRCUIT
3
4
D255EL03
7-4
2. STARTING CIRCUIT
1) OPERATING FLOW
Battery(+) terminal Start motor[CN-45(B+)] Fusible link[CN-95A] Start switch[CS-2(3)]
Safety relay[CR-23, 2P(1)]
Fusible link[CN-95B] QGS controller[CR-24, 2P(2)]
※T
The engine can be started only when the gearshift is in neutral position.
(1) When start key switch is in ON position
Start switch ON [CS-2(4)] Fuse box[No. 6→7] [CN-2(4)] Fuel shut off solenoid[CN-79]
Fuse box[No. 6→8] I/conn[CN-1(5)] QGS controller[CR-24, 6P(3)]
Glow plug[CN-80]
Preheating(OFF in 8sec)
Safety relay[CR-23, 6P(3)]
(2) When start key switch is START position
Start switch START[CS-2(2)] Fuse box[CN-36(1)] Flasher unit/relay[CR-11(13)→(5)]
I/conn[CN-1(10)] QGS controller[CR-24, 6P(1)] Preheating(Only when key holded)
Safety relay[CR-23, 6P(1)] Starter
2) CHECK POINT
① - GND (Battery B+)

② - GND (Fusible link)
Running ON ③ - GND (Fuse box No.12) 10 ~ 14.5V
④ - GND (Start key)
⑤ - GND (Safety relay)
7-5
STARTING CIRCUIT
D255EL04
7-6
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-95A)
and the fuse box.
1) OPERATING FLOW
(1) Warning flow
Alternator[CN-74(L)] I/conn[CN-2(1)] Cluster charging warning lamp ON[CN-56(13)]
(2) Charging flow
Alternator[CN-74(B+)] Fusible link[CN-95A] Starter motor[CN-45(B+)]
Battery (+)terminal Charging
2) CHECK POINT
① - GND (Alternator B+)

ON ON ② - GND (Start key) 10 ~ 14.5V
③ - GND (Operating panel)
※ GND : Ground
※ 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.
7-7
CHARGING CIRCUIT
2
3
D255EL05
7-8
GROUP 3 COMPONENT SPECIFICATION
No Part name Qty Specification Remark
1 Battery 1 CCA : 720A

20HR : 90AH CMF 90(322×172×213)
2 Working lamp 1 12V, 55W
3 License lamp 1 12V, 3.4W×12
4 Combination lamp 2 12V, 21W(T/S) 12V, 10W(Back)
12V, 5W (Tail)
12V, 21W(Stop)
5 Head lamp 2 12V, 55W
6 Flasher lamp 2 12V, 23/8W
7 Flasher & Relay 1 12V, 20A (Relay)
12V, (21W+21W)×2+3W(Flasher)
130W (Harzard)
8 Back horn 1 12V, 90±5dB, 60±10C/M
9 Horn 1 12V, MAX 3.5A, 105~120dB
10 Fuel level sender 1 Reed switch - Magnet type
Float indicate E 1/2 F
Resistance[Ω] 95 32.5 7
Allowance[Ω] ±2.5 ±5 ±2.5
11 Master switch 180A

12 Combination switch 1 12V, 10A
13 Hazard switch 1 12V, 16A
14 Start switch 1 12V/24V, 15~28A
15 QGS Controller 1 12V, 40A, op time : 8±1.6sec(key ON)
16 Safety relay 1 12V, 40A(Contact point capacity)
Automatically broken at 1350rpm of alternator.
7-9
Connector No. of Connector part No.
number Type Destination
pin Female Male
CN-1 KET 8 I/conn(Dashboard harness-frame harness) S814*008001 S814-108001
CN-2 KET 14 I/conn(Dashboard harness-frame harness) S814-014100 S814-114100
CN-3 KET 1 I/conn(Dashboard harness-frame harness) MG640944-5 MG650943-5
CN-4 AMP 4 Support harness-LH S810-004202 -
CN-5 MOLEX 4 Support harness-RH 110-4P-F -
CN-17 KET 4 Power output S814-004100 -
CN-18 KET 2 Power S814-002100 -
CN-25 MOLEX 2 Horn 35825-0211 -
CN-26 KET 2 Warning buzzer S814-002100 -
CN-48 KET 2 Hour meter S822-014000 S822-114000
CN-56 MOLEX 20 Operating panel 35109-2010 -
CN-58 KET 8 Detector S813-030201 -
CN-65 KET 2 Back horn S822-014000 S822-114000
CN-74 SUMITOMO 3 Alternator 6189-0442 -
CN-79 YAZAKI 2 Fuel solenoid valve S812-001003 -
CN-95A KET 2 Fusible link - S813-130201
CN-95B KET 2 Fusible link - S813-130201
CN-122 KET 2 Forward solenoid S812-002001 -
CN-123 KET 2 Reverse solenoid S812-002001 -
Switch
CS-2 AMP 4 Start switch S810-004202 -
CS-11 AMP 5 Combinaton switch S811-005002 -
CS-12 AMP 9 Combinaton switch S811-009002 -
CS-21 SWF 10 Work lamp switch 593757 -
CS-23 SWF 10 Beacon lamp switch 593757 -
CS-41 SWF 10 Harzard switch 593757 -
Lamp
CL-7 KET 6 Beacon lamp S822-014000 S822-114000
CL-15 DAEDONG 6 Combination lamp-LH 110-6PR -
CL-16 DAEDONG 6 Combination lamp-RH 110-6PR -
CL-21 KET 2 License lamp S822-014000 S822-114000
CL-23 KET 2 Working lamp S822-014000 S822-114000
Relay
CR-11 KET 13 Flasher unit relay S811-001301 -
CR-23 SUMITOMO 2/6 Safety relay 6195-0060/21 -
CR-24 SUMITOMO 2/6 QGS Controller 6195-0060/21 -
CR-35 AMP 4 Warning relay S810-004202 -
7-10
Connector No. of Connector part No.
number Type Destination
pin Female Male
Sensor and pressure switch
CD-2 KET 3 Fuel level sensor S810-003201 -
CD-4 KET 2 Brake switch S822-014000 -
CD-8 AMP 1 Water temp sender S819-010122 -
CD-9 AMP 1 Water temp switch S819-010122 -
CD-10 DAEDONG 2 Air cleaner switch 110-6PR -
CD-18 KET 1 Engine oil pressure sender S822-014000 -
CD-29 AMP 1 T/M temp switch S819-010122 -
CD-38 - 2 Fuel water separator S816-002003 -
CD-48 AMP 2 Diode 174352-2 -
7-11
GROUP 4 TROUBLESHOOTING

Lamps dimming even at maxi- ·Faulty wiring. ·Check for loose terminal and discon-
mum engine speed. nected wire.
Lamps flicker during engine ·Improper belt tension. ·Adjust belt tension.
operation.
Charge lamp does not light d- ·Charge lamp defective. ·Replace.
uring normal engine operation. ·Faulty wiring. ·Check and repair.
Alternator makes abnormal ·Alternator defective. ·Replace
sounds.
Starting motor fails to run. ·Faulty wiring. ·Check and repair.
·Insufficient battery voltage. ·Recharge battery.
Starting motor pinion repeats ·Insufficient battery voltage. ·Recharge battery.
going in and out.
Excessively low starting motor ·Insufficient battery voltage. ·Recharge battery.
speed. ·Starting motor defective. ·Replace
Starting motor comes to a stop ·Faulty wiring. ·Check and repair.
before engine starts up. ·Insufficient battery voltage. ·Recharge battery.
Heater signal does not beco- ·Faulty wiring. ·Check and repair.
me red. ·Glow plug damaged. ·Replace
Engine oil pressure caution ·Caution lamp defective. ·Replace
lamp does not light when enig- ·Caution lamp switch defective. ·Replace
ne is stopped
(with starting switch left in"ON"
position).
7-12
SECTION 8 MAST
Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1

Group 2 Operational Checks and Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-5
Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-8
Group 4 Removal and Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-11
SECTION 8 MAST
GROUP 1 STRUCTURE
1. 2 STAGE MAST(V MAST)
4
3
5
7
8
2 TILT CYLINDER
9
LIFT CYLINDER
11
CARRIAGE 10
13
12
D255MS01
1 Outer mast 6 Anchor bolt 10 Trunnion cap

2 Inner mast 7 Chain wheel bearing 11 Bushing
3 Roller 8 Retaining ring 12 Roller
4 Shim(0.5, 1.0t) 9 Tilt cylinder pin 13 Shim(0.5, 1.0t)
5 Chain
8-1
2. 2 STAGE MAST(VG MAST)
8
7
6
5
12
14 1
13
4 TILT CYLINDER
LIFT CYLINDER
FREE LIFT CYLINDER
11
10
CARRIAGE
D255MS02
1 Outer mast 6 Shim(0.5, 1.0t) 11 Bushing

2 Inner mast 7 Roller 12 Sheave
3 Chain 8 Shim(0.5, 1.0t) 13 Sheave bracket
4 Anchor bolt 9 Tilt cylinder pin 14 U-bolt
5 Back up liner 10 Support cap
8-2
3. 3 STAGE MAST(TF MAST)
7
6
5 15
11
9
8
1
12
3
TILT CYLINDER
11
10 14
13
LIFT CYLINDER
FREE LIFT CYLINDER
CARRIAGE
D255MS021
1 Outer mast 6 Roller 11 Sheave

2 Middle mast 7 Shim(0.5, 1.0t) 12 Tilt cylinder pin
3 Inner mast 8 Back up liner 13 Support cap
4 Chain 9 Shim(0.5, 1.0t) 14 Bushing
5 Anchor bolt 10 Sheave bracket 15 U-bolt
8-3
4. CARRIAGE, BACKREST AND FORK
3
2
D255MS03
1 Backrest 3 Load roller 5 Fork assembly

2 Carriage 4 Side roller 6 Extension fork
8-4
1) FORKS
(1) Measure thickness of root of forks and
check that it is more than specified value.
EX : ℓ=1050mm(41.3in)
mm(in)
STD Fork assy Applicable model Standard Limit
Thickness
F173796-02 HDF20/25-5 45(1.8) 40(1.6) Limit : within 10% of original
64FG-31020 HDF30-5 45(1.8) 40(1.6)
D255FK01
(2) Set forks in middle and measure out of

parallel and difference in height at top of
forks. Out of parallel
mm(in)
Difference in height Max 15(0.6)
Out-of-parallel Max 35(1.4)
Difference in height
at tip of forks
D255FK02
(3) Most force is concentrated at root of fork

and at hook, so use crack detection
method to check cracks.
2. MAST
1) Check for cracks at mast stay, tilt cylinder bracket, guide bar, fork carriage and roller shaft weld.
Check visually or use crack detection method. Repair any abnormality.
2) Set mast vertical, raise forks about 10cm from ground and check front-to-rear clearance and left-to-
right clearance between inner mast and fork carriage, and between outer mast and inner mast.
Use these figures to judge if there is any play at roller or rail.
·Front-to-rear clearance : Within 2.0mm(0.08in)
·Left-to-right clearance : Within 2.5mm (0.10in)
3) Check that there is an oil groove in bushing at mast support.
4) Set mast vertical, raise forks about 10cm from ground, and push center of lift chain with finger to
check for difference in tension.
If there is any difference in tension, adjust chain stopper bolt.
5) Check visually for abnormalities at thread of chain anchor bolt, and at contact surface between
chain wheel and chain.
Rotate chain wheel by hand and check for any play of bearing.
8-5
2. TROUBLESHOOTING
1) MAST
Forks fail to lower. ·Deformed mast or carriage. ·Disassemble, repair or replace.
Fork fails to elevate ·Faulty hydraulic equipment. ·See troubleshooting hydraulic pump
and cylinders in section 6, hydraulic
system.
·Deformed mast assembly. ·Disassemble mast and replace
damaged parts or replace complete
mast assembly.
Slow lifting speed and ·Faulty hydraulic equipment. ·See troubleshooting hydraulic pump
insufficient handling capacity. and cylinders in section 6, hydraulic
system.
·Deformed mast assembly. ·Disassemble mast and replace
damaged parts or replace complete
mast assembly.
Mast fails to lift smoothly. ·Deformed masts or carriage. ·Disassembly, repair or replace.
·Faulty hydraulic equipment. ·See Troubleshooting Hydraulic
Cylinders, pump and control valve in
section 6, hydraulic system.
·Damaged load and side rollers. ·Replace.
·Unequal chain tension between ·Adjust chains.
LH & RH sides.
·LH & RH mast inclination angles ·Adjust tilt cylinder rods.
are unequal. (Mast assembly is
twisted when tilted)
Abnormal noise is produced ·Broken load roller bearings. ·Replace.
when mast is lifted and lower- ·Broken side roller bearings. ·Replace.
ed. ·Deformed masts. ·Disassemble, repair or replace.
·Bent lift cylinder rod. ·Replace.
·Deformed carriage. ·Replace.
·Broken sheave bearing. ·Replace.
Abnormal noise is produced ·Insufficient lubrication of anchor ·Lubricate or replace.
during tilting operation. pin, or worn bushing and pin.
·Bent tilt cylinder rod. ·Replace.
8-6
2) FORKS

Abrasion Long-time operations causes the fork to If the measured value is below the wear
wear and reduces the thickness of the limit, replace fork.
fork.
Inspection for thickness is needed.
·Wear limit : Must be 90% of fork
thickness
Distortion Forks are bent out of shape by a If the measured value exceeds the
number of reasons such as allowance, replace fork.
overloading, glancing blows against
walls and objects, and picking up load
unevenly.
·Difference in fork tip height : 15mm
·Difference in fork tip width : 35mm
Fatigue Fatigue failure may result from the Repair fork by expert.
fatigue crack even though the stress to In case of excessive distortion, replace
fork is below the static strength of the fork.
fork. Therefore, a daily inspection
should be done.
·Crack on the fork heel.
·Crack on the fork weldments.
8-7
GROUP 3 ADJUSTMENT
1. MAST LOAD ROLLER(V, VF MAST)
1) INNER/OUTER MAST ROLLER CLEARANCE
ADJUSTMENT
(1) Measure the clearance with the mast
overlap at near 480mm.
(2) Shift the inner mast to one side to bring
the roller into contact with the outer mast,
and adjust the clearance between the
roller side face and mast at the closest
position on the opposite side to the L15C3MS04
following value by inserting the inner/outer

mast roller shim.
·Standard clearance A, B = 0~0.6mm
·Shim thickness 0.5, 1.0mm
(3) Distribute the shim thickness equally to
the left and right roller. Refer to Mast load
roller and back up liner, removal and
Installation.
(4) After the adjustment, check that the inner
mast moves smoothly in the outer mast.
L15C3MS05
8-8
2. MAST LOAD ROLLER(TF MAST)
1) INNER AND MIDDLE MAST ROLLER
CLEARANCE ADJUSTMENT
the roller into contact with the outer mast
and the middle mast, and adjust the
clearance between the roller side face and
mast at the closest position on the L15C3MS06
opposite side to the following value by

inserting the inner and middle mast roller
shim, respectively.
·Standard clearance A = 0~0.6mm
the left and right roller. Refer to Mast load
roller and back up liner, removal and
Installation.
(4) After the adjustment, check that the inner
mast moves smoothly in the middle mast,
and the middle mast moves smoothly in
the outer mast.
2) OUTER AND MIDDLE MAST UPPER

ROLLER CLEARANCE ADJUSTMENT.
the roller into contact with the outer mast
and the middle mast, and adjust the
clearance between the roller side face and
mast at the closest position on the L15C3MS07

inserting the outer and middle mast roller
shim, respectively.
·Standard clearance B = 0~0.6mm
(3) Distribute the shim thickness equally to the left and right roller. Refer to Mast load roller and back
up liner, removal and lnstallation.
(4) After the adjustment, check that the inner mast moves smoothly in the middle mast, and the
middle mast moves smoothly in the outer mast.
8-9
3) CARRIAGE LOAD ROLLER
Adjust Bring into Outer mast
(1) Measure the clearance when the center of screw contact
the carriage upper roller is 100mm from
100mm
the top of the inner mast.
(2) Measure the clearance at upper, middle Side
and lower rollers after loosen the adjust roller Carriage
screws from the side rollers. Shift the Bring into
contact
carriage to one side to bring the roller into C
contact with the inner mast, and measure Inner mast
the clearance between the roller side face D255MS08
and mast at the closest position on the

inserting the carriage roller shim.
·Standard clearance C = 0~0.6mm
the left and right roller. Refer to Carriage
assembly.
(4) After the adjustment, the carriage should
move smoothly along the overall mast
length.
4) MAST BACK UP LINER

(1) Measure the clearance with the middle
mast at the bottom position.
(2) With the middle mast in contact with the
outer mast roller, adjust the clearance
between the mast back up liner and
middle mast to the following value by
inserting the back up liner shim.
·Standard clearance E = 0.2 ~ 0.6mm L15C3MS09

(3) After the adjustment, the mast should
move smoothly.
8-10
GROUP 4 REMOVAL AND INSTALLATION
1. FORKS
1) Lower the fork carriage until the forks are
approximately 25mm(1inch) from the floor.
2) Release fork anchor pins and slide forks,
one by one, toward the center of the
carriage where a notch has been cut in the
bottom plate for easy fork removal.
3) Remove the fork one by one. On larger forks
it may be necessary to use a block of wood.
4) Reverse the above procedure to install load
forks. L15C3MS10
2. BACKREST
1) Remove bolts securing backrest to fork
carriage. Lift backrest straight up and Backrest
remove from carriage.
2) Position backrest on carriage and lower in
place. Install and tighten bolts.
Carriage
Bolt
D255MS11
3. CARRIAGE ASSEMBLY
1) CARRIAGE
(1) With the mast vertical, raise the carriage high enough to place blocks under the load forks. This is
done to create slack in the load chains when the carriage is lowered. Lower the carriage all the
way down to the floor. Make sure the carriage is level, this will prevent any binding when the mast
is raised.
(2) While supporting lift chains, remove the split pin and slide out chain anchor pins from the chain
anchors of stationary upright.
(3) Pull the chains out of the sheaves and drape them over the front of the carriage.
(4) Slowly raise elevating upright until mast clears top of fork carriage. Move carriage to work area
and lower mast.
Make sure carriage remains on floor and does not bind while mast is being raised.
(5) Inspect all parts for wear or damage. Replace all worn or damaged pars.
(6) Reverse the above steps to reinstall.
Replace the split pin of chain anchor with new one.
8-11
2) SIDE ROLLER
(1) Remove carriage as outlined in the carriage
assembly and removal paragraph.
(2) Loosen and remove nuts, adjust screws
and side rollers from carriage side pate.
(3) Thoroughly clean, inspect and replace all
worn or damaged parts.
(4) Reverse the above procedure to assembly.
※ Adjustment
· Once carriage is properly installed,
loosen nuts and adjust screws, (if not D255MS12
already done) allowing carriage to be

centered in the inner mast.
· Adjust side roller by tightening screw until
side roller just makes contact with mast.
Back off approximately 1/10 turn on
screw and tighten nut to lock screw in
place.
· Run carriage up and down for the inner
mast to be sure the carriage has free
movement and does not stick. Also,
make sure chains are properly adjusted.
Refer to chain adjustment paragraph.
Make adjustment when necessary and
recheck operation of carriage.
3) CARRIAGE LOAD ROLLER

(1) Remove carriage as outlined in the
Carriage
carriage assembly removal paragraph. load roller
(2) Loosen and remove flat head bolts and
plain washers from top load roller bracket.
(3) Using a pryer, remove load rollers from
load roller bracket.
(4) Reverse the above procedure to assemble.
Refer to MAST ROLLER ADJUSTMENT
paragraph.
D255MS13
8-12
4) MAST LOAD ROLLER AND BACK UP LINER
(1) 2 stage mast(V mast)
① Remove the carriage assembly and Chain
move them to one side.
② Loosen and remove hexagon bolts and Stud
bolt
washers securing lift cylinders to inner Inner
mast
mast.
③ Loosen and remove hexagon bolts and Backup
nuts securing lift cylinders to inner mast. liner
④ Attach chains or sling to the inner mast
section at top crossmember. Using an
overhead hoist, slowly raise the inner
mast high enough to clear lift cylinder.
⑤ After lowering the lift cylinder rods, and
disconnecting lift cylinder hose, tilt the lift LIft
cylinders LH and RH and them with Cylinder cylinder
ropes to the outer mast. band
⑥ Using the overhead hoist, lower inner Outer

mast
mast until top and bottom rollers and
back up liners are exposed.
⑦ Using a pryer, remove load rollers from
load roller bracket. Remove back up
liners and shims.
⑧ Thoroughly clean, inspect and replace all
Bolt
worn or damaged parts. Mast
⑨ Reverse the above procedure to load
roller
assemble. Refer to MAST LOAD
ROLLER ADJUSTMENT paragraph. D255MS14
8-13
(2) 2 stage mast(TF mast)
① Remove free lift chain connected
between carriage and free lift cylinder.
Chain
② Remove the carriage assembly and
move them to one side. Stud
③ Loosen and remove hexagon bolts and bolt
Inner
washers securing lift cylinders to inner mast
mast.
④ Loosen and remove hexagon bolts and Backup
liner
nuts securing lift cylinders to inner mast.
⑤ Attach chains or sling to the inner mast
section at top crossmember. Using an
overhead hoist, slowly raise the inner Carriage
mast high enough to clear lift cylinder.
⑥ After lowering the lift cylinder rods, and Free LIft
disconnecting lift cylinder hose, tilt the lift cylinder
Cylinder
cylinders LH and RH and them with band
ropes to the outer mast. Outer
⑦ Using the overhead hoist, lower inner mast
mast until top and bottom rollers and
back up liners are exposed.
LIft
⑧ Using a pryer, remove load rollers from cylinder
load roller bracket. Remove back up
liners and shims.
⑨ Thoroughly clean, inspect and replace all Bolt
Mast
worn or damaged parts. load
⑩ Reverse the above procedure to assem- roller
ble. Refer to MAST LOAD ROLLER
ADJUSTMENT paragraph. D255MS141
8-14
(3) 3 stage mast(TF mast)
① Remove the carriage assembly and
move to one side.
② Loosen and remove hexagon bolt
securing bottom cylinder from outer mast.
③ Loosen and remove bolts and special
washers securing lift cylinders to middle
mast.
④ Attach chains or sling to the inner and
middle mast section at top crossmember.
Using an overhead hoist, slowly raise the
uprights high enough to clear lift cylinder.
⑤ After lowering the lift cylinder rods, and
disconnecting lift cylinder hose, tilt the lift
cylinders LH and RH and tie them with
ropes to the outer mast.
⑥ Using the overhead hoist raise inner and
middle masts. Place 4 inch block of
wood under the free lift cylinder bracket of
the inner mast then lower mast sections
(this will create slack in the chains).
Remove retaining rings securing chain
⑦ sheaves to sheave support brackets.
While support chains, remove chain
sheaves and let chains hang free. The
upper outer and lower middle mast rollers
and back up liners are now exposed.
Using a pryer, remove load rollers from
⑧ load bracket. Remove back up liners and
shims.
Attach chains or sling to the middle mast
⑨ section at top crossmember. Using an
overhead hoist, slowly raise the middle
mast until top and bottom rollers are
exposed.
Using a player, remove load rollers from
⑩ load roller bracket.
Thoroughly clean, inspect and replace all
⑪ worn or damaged parts.
Reverse the above procedure to
⑫ assemble. Refer to MAST LOAD
ROLLER ADJUSTMENT paragraph.
D255MS15
8-15
5) ELEVATING MAST
(1) Inner mast (V, VF mast)
① After completing all necessary steps for load rollers and back up liner removal use an overhead
hoist and sling or chain around upper crossmember of the inner mast section.
② Lift inner mast upright straight up and out of outer mast section.
③ Replace and reverse above procedure to install. Make all necessary measurements and
adjustments.
(2) Inner and middle mast(TF mast)
① After completing all necessary steps for load rollers and back up liner removal. Remove rear
chains and sheave support if not already done.
② Disconnect free lift cylinder hose. Drain hose into a suitable pan or container and cap hose.
③ While supporting free lift cylinder assembly, remove bolts and washers securing cylinder to mast
crossmember.
④ Place a sling around free lift cylinder and attach to an overhead hoist. Slowly raise and move
cylinder to one side.
⑤ Attach chains or sling to the inner mast section at top crossmember. Using an overhead hoist
slowly raise the upright straight up and out of middle mast section.
⑥ Attach chains or sling to the middle mast section at top crossmember. Using an overhead hoist
slowly raise the upright straight up and out of outer mast section.
⑦ Replace upright and reverse above procedure to install. Make all necessary measurements and
adjustments.
8-16
6) CHAIN
Chain Outer mast
(1) Chain sheave(V, VF mast)
① Place a sling around carriage and attach Sheave
to an overhead hoist. Lift carriage high
enough so that the tension on the chain
over sheaves is relieved after the carriage
is blocked. Position wooden blocks under
the carriage and lower it. Inner
② Remove the split pin securing the chain mast
anchor pins and discard. While

supporting the chains, remove the chain Carriage
anchor pins and drape the chains over the VF mast only
③ carriage.
Chain
Remove retaining ring securing sheaves
to sheave support. Remove sheaves Sheave
④ with bearings.
Remove bearining retaining ring from Sheave
⑤ sheave and press bearings from sheaves. Anchor
bolt
Thoroughly clean, inspect and replace all
⑥ worn or damaged parts.
Reverse the above to assemble and install. D255MS16
(2) Rear chain sheave(TF mast)

Middle mast
① Raise and securely block carriage and Sheave
Chain
inner mast section.
② Remove the split pin securing the chain Chain
anchor pins and discard. While
supporting the chains, remove the chain
anchor pins from outer mast section.
③ Remove chains.
④ Remove retaining ring securing chain
sheaves to sheave support. Pry off
sheaves with bearings.
⑤ Remove bearing retaining ring from
sheave and press bearings from
sheaves.
⑥ Thoroughly clean, inspect and replace all Anchor
worn or damaged parts. bolt
⑦ Reverse the above procedure to

assemble and install. Use new split pins
in chain anchor pins. Inner mast
Anchor
bolt Free lift cylinder
Carriage
D225MS17
8-17
(3) Chain wheel bearing support(TF mast)
① Remove the carriage assembly and move to one side.
② After removing bolt to securing chain wheel bearing support assembly to free lift cylinder.
After a sling to the chain wheel bearing support assembly. Using an overhead hoist, lift support
assembly straight up and off of free lift cylinder. Move assembly to work area.
③ Remove retaining ring securing chain wheel bearing to chain wheel bearing support.
④ Remove bearing retaining ring from chain wheel bearing and press bearings from chain wheel
bearings.
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 chain wheel bearings, the joints very gradually wear. The
stretch a chain developes in service is due to material being worn off pin outer diameter and pitch
hole inner diameter on the inside plate.
Chain wear can be measured using a wear scale or steel tape. When chains have elongated
2%, they should be discarded. When checking chain wear, be sure to measure a segment of
chain that operates over a sheave. Do not repair chains by cutting our the worn section and
splicing in a new piece. If part of the chain is worn, replace all the chains on the truck.
8-18
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 penomenon 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 :
·Bent pins or plates.
·Rusty joints.
·Peened 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 chain wheel bearings
An inspection of the chain system includes a close examination of chain anchors and chain
wheel bearings. Check chain anchors for wear, breakage and misalignment.
Anchors with worn or broken fingers should be replaced. Anchors should be adjusted to
eliminate twisting or other misalignment in the chain. When chain is misaligned, load is not
distributed uniformly between the plates. Prolonged operation will result in premature fatigue
failure. Chain wheel bearings with badly worn flanges and outside diameter should be replaced.
Heavy flange wear indicates chain misalignment.
8-19
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 :
·Determine pitch length of chain using 6 inch scale on one side of wear scale.
·If 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.
·If pitch is 5/8(15.875mm), 1-1/4(31.75mm) or 2(50.8mm), use side B.
·Align point A or B to center of a pin and note position of the opposite A or B point.
·If 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.
·Wipe off the old oil with a clean cloth and blow out the remaining dirt with compressed air.
Wear eye protection.
·With 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 jonts in the old chain will be
greater than that on the new chain, greatly complicating the problem of maintaining equal chain
tension. The new chain will wear more slowly causing it to bear the major portion of the load
resulting in premature wear and fatigue failure. Don’t steam clean or decrease new chains.
The manufacturer’s grease is effective in reducing wear and corrosion. If the original factory lube
is dried out or wiped off, soak the new chain in heavy engine oil for at 1/2 hour prior to installing
on truck. After the old chains have been stripped from the mast, very carefully inspect chain
anchors and chain wheel bearing. Broken, cracked or worn anchor must be replaced using the
new anchor pin and split pin. Do not paint newly replaced chain after it has been installed.
8-20
③ Adjustment
Chain adjustments are important for the following reasons :
·Equal loading of chain.
·Proper sequencing of mast.
·Prevent over-stretching of chains.
·Prevent chains from jumping off sheaves if they are too loose.
④ Adjustment procedure
·With mast in its fully collapsed and vertical position, lower the fork to the floor.
·Adjust the chain length by loosening or tightening nut on the chain anchor.
After making adjustment on the mast, be sure to tighten the nut.
8-21

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CONTENTS

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

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 1ℓ = 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

Group 1 Safety Hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1

Careless performing of the easy work may cause injuries.

· Wear well-fitting helmet, safety shoes and

· Flames should never be used instead of

· Exhaust gas is dangerous. Provide adequate

· When working on top of the machine, be

· Hand a caution sign in the operator's compartment

When inspecting the engine is running parts, or

· When working with others, choose a group

· Unless you have special instructions to the

· Always remember that the hydraulic oil circuit

1 Mast 7 Forks 12 Bonnet

Model Unit HDF 20-5 HDF 25-5 HDF 30-5

Capacity kg 2000 2500 3000

ITEM UNIT SPECIFICATION

Model - YANMAR 4TNE98-HYF(IDI)

ITEM UNIT SPECIFICATION

Type - Fixed displacement gear pump

3) MAIN CONTROL VALVE

ITEM UNIT SPECIFICATION

Type 3 Element, 1 stage, 2 phase

1 Engine mounting bolt, nut M16×2.0 7.5 54

(2) Fine thread

Thread size(PF) Width across flat mm kgfÂm lbfÂft

3) PIPE AND HOSE(ORFS TYPE)

Thread size(UNF) Width across flat mm kgfÂm lbfÂft

Thread size(PF) Width across flat mm kgfÂm lbfÂft

SAE 80W-90/API GL-5(DRY)

ASTM D975 No.1

Fitting NLGI No.1

Brake DOT III(DRY)

No Description Period of replacement

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

1 Mast 9 Transmission 17 Muffler