Hyundai Diesel Models

20 ~33D-7

New Style for 7A

New Version

Control Block Function

Clutch Operation

When (forward/reverse) mode is selected through the solenoid valve

in the control valve, the Hydraulic pressure from the pump flows
into forward (reverse) clutch pack at 9~14.2kgf/cm2(128~202 psi) of
pressure through the oil delivery lines in the Shaft. This oil makes
plugging of clutch pack by delivering pressure to the clutch piston. At
this time the clutch shaft is revolving while connected with the
turbine of torque converter. With the clutch engaged the clutch drum
also rotates allowing the drive power to connect through the gear to
the output side of the transmission.

Drive Axle

Wet Disc Brake

Carrier sub assy includes differential device and parking brake. The pinion shaft is
supported by the taper roller bearing in the carrier case and the bolt at the end of
pinion shaft,This transfers the power which is delivered from the drive shaft assy to
the ring gear assembled from bolts at a differential device. This power makes the
differential device run. Since the differential device is connected with an axle shaft
and a spindle, the power transferred to differential device is delivered to final drive
through the axle shaft. Parking brake, The park brake system consists of several
friction plate alternating between Brake plate and steel plate and are activated when
the Park brake lever is pulled.

OPERATION
The torque converter is connected with a flywheel by a flexible plate,
engine output is delivered from
the flywheel to the flexible plate.
The exterior of the torque converter is protected by the torque converter
housing.
The torque converter housing forms the oil path for the oil pump, it
includes the oil strainer filtering
sucked oil through this oil path and the oil level gauge measuring oil level
of the transmission inside.

Transmission
New Version Version

Hydraulic Diagram of the Control Valve

The control valve consists of the main relief valve, inching valve,
accumulator valve and directional valve.
The discharged oil from the gear pump enters the main relief valve of the
control valve and the pressure is adjusted 10.8~14.9kgf/cm2
(154~212psi).
The Solenoid valves direct the oil pressure to Forward or Reverse
clutches.
Power is transferred from the torque converter to drive axle through the
Forward or Reverse clutch direction.
The remaining oil pressure flows into the torque converter through the
input pressure control port.
At this time, the oil pressure input to the torque converter is adjusted
4~7kgf/cm2 (57~100psi), the oil pressure output from the torque converter
is adjusted below 7kgf/cm2 (100psi).
The oil which passes through the Torque Converter is directed to the
Transmission cooler where it is cooled before returning to the
Transmission to cool and lubricate the Clutches and the Bearings.
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 valve permits the clutch to partially disengage, so that engine
rpm can be increased for lifting while travel speed remains low.

Power Train Troubleshooting 1/4

2/4

4/4

Inching Pedal and Linkage

Inching Pedal and Linkage

The brake pedal is used to actuate the hydraulic brakes on the
drive axle. At the beginning of the pedal stroke, the inching spool
of the transmission control valve is actuated to shift the hydraulic
clutch to neutral and turn off the driving force. By treading the
pedal further, the brake is applied.

Adjusting the Inching Pedal

Brake Valve

Parking Brake

Troubleshooting

Steering System

Operational Checks

Hydraulic System (OPSS and Boosted Brakes)

Pump Inlet Port to MCV

Hoist Lift Circuit

Hoist Lower Position

Forward Tilt

Tilt Backwards

Lift Cylinder

Tilt Cylinder

Free Lift Cylinder

Electrical

Main Harness

Frame/ Engine Part

Component Specs

Connector Destinations

Connector Destinations

Troubleshooting

MAST

(V) MAST
2 Stage

(VF) MAST
2 Stage with Low Free Lift

(TF) MAST
Three stage High Free Lift

Chain Maintenance
Replacement
Replace chains as a pair. It will be virtually impossible to maintain uniform
loading between the strands if a new chain is put into service opposite an old
chain. The joints in the old chain will be greater than that on the new chain,
greatly complicating the problem of maintaining equal chain tension. The new
chain will wear more slowly causing it to bear the major portion of the load
resulting in premature wear and fatigue failure. Dont steam clean or
decrease new chains, The manufacturers 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.

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.
NOTE
Wear eye protection.
With a clean brush, apply EP-140 extreme pressure lubricant or heavy
motor oil(40W).

Chain Maintenance

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.
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.

Carriage, Backrest and Fork

Troubleshooting Mast

Troubleshooting Forks

Operational Checks

V & VF Mast Adjustment

TF Mast Adjustment

Roller Clearance

Carriage Load Roller Adjustment

Mast Back Up Liner