PDF Service Manual Hyundai 35D-9S 40D-9S 45D-9S 50D-9SA Forklift - 1 MB
This comprehensive service manual covers the Hyundai 9S-series diesel forklifts, including the 35D-9S, 40D-9S, 45D-9S, and 50D-9SA models.
It is an essential resource for technicians, providing detailed instructions for repair, maintenance, and troubleshooting.
The manual includes information on the engine, hydraulics, and electrical systems.
Keep your Hyundai forklift fleet in excellent condition with this in-depth guide.
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--- Page 1 ---
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 Inspection and troubleshooting ------------------------------------------------------------------------ 3-13
Group 3 Disassembly and assembly ------------------------------------------------------------------------------ 3-21
SECTION 4 BRAKE SYSTEM
Group 1 Structure and function --------------------------------------------------------------------------------------- 4-1
Group 2 Operational checks and troubleshooting --------------------------------------------------------- 4-8
Group 3 Tests and adjustments -------------------------------------------------------------------------------------- 4-10
SECTION 5 STEERING SYSTEM
Group 1 Structure and function --------------------------------------------------------------------------------------- 5-1
Group 2 Operational checks and troubleshooting --------------------------------------------------------- 5-10
Group 3 Disassembly and assembly ------------------------------------------------------------------------------ 5-12
SECTION 6 HYDRAULIC SYSTEM
Group 1 Structure and function -------------------------------------------------------------------------------------- 6-1
Group 2 Operational checks and troubleshooting -------------------------------------------------------- 6-15
Group 3 Disassembly and assembly ----------------------------------------------------------------------------- 6-20
SECTION 7 ELECTRICAL SYSTEM
Group 1 Component location ------------------------------------------------------------------------------------------ 7-1
Group 2 Electrical circuit -------------------------------------------------------------------------------------------------- 7-2
Group 3 Component specification ---------------------------------------------------------------------------------- 7-12
Group 4 Connector destination --------------------------------------------------------------------------------------- 7-13
Group 5 Troubleshooting -------------------------------------------------------------------------------------------------- 7-15
--- Page 3 ---
SECTION 1 GENERAL
Group 1 Safety hints --------------------- ------------------------------------------------------------------------------------ 1-1
Group 2 Specifications ----------------------------------------------------------------------------------------------------- 1-5
Group 3 Periodic replacement ---- ------------------------------------------------------------------------------------ 1-13
--- Page 4 ---
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 2.73 ~ 4.12 19.7 ~ 29.8
M10 × 1.5 4.0 ~ 6.0 28.9 ~ 43.4 5.5 ~ 8.3 39.8 ~ 60
M12 × 1.75 7.4 ~ 11.2 53.5 ~ 79.5 9.8 ~ 15.8 71 ~ 114
M14 × 2.0 12.2 ~ 16.6 88.2 ~ 120 16.7 ~ 22.5 121 ~ 167
M16 × 2.0 18.6 ~ 25.2 135 ~ 182 25.2 ~ 34.2 182 ~ 247
M18 × 2.5 25.8 ~ 35.0 187 ~ 253 35.1 ~ 47.5 254 ~ 343
M20 × 2.5 36.2 ~ 49.0 262 ~ 354 49.2 ~ 66.6 356 ~ 482
M22 × 2.5 48.3 ~ 63.3 350 ~ 457 65.8 ~ 98.0 476 ~ 709
M24 × 3.0 62.5 ~ 84.5 452 ~ 611 85.0 ~ 115 615 ~ 832
M30 × 3.5 124 ~ 168 898 ~ 1214 169 ~ 229 1223 ~ 1655
M36 × 4.0 174 ~ 236 1261 ~ 1703 250 ~ 310 1808 ~ 2242
(2) Fine thread
8T 10T
Bolt size
kgf·m lbf·ft kgf·m lbf·ft
M 8 × 1.0 2.17 ~ 3.37 15.7 ~ 24.3 3.04 ~ 4.44 22.0 ~ 32.0
M10 × 1.25 4.46 ~ 6.66 32.3 ~ 48.2 5.93 ~ 8.93 42.9 ~ 64.6
M12 × 1.25 7.78 ~ 11.58 76.3 ~ 83.7 10.6 ~ 16.0 76.6 ~ 115
M14 × 1.5 13.3 ~ 18.1 96.2 ~ 130 17.9 ~ 24.1 130 ~ 174
M16 × 1.5 19.9 ~ 26.9 144 ~ 194 26.6 ~ 36.0 193 ~ 260
M18 × 1.5 28.6 ~ 43.6 207 ~ 315 38.4 ~ 52.0 278 ~ 376
M20 × 1.5 40.0 ~ 54.0 289 ~ 390 53.4 ~ 72.2 386 ~ 522
M22 × 1.5 52.7 ~ 71.3 381 ~ 515 70.7 ~ 95.7 512 ~ 692
M24 × 2.0 67.9 ~ 91.9 491 ~ 664 90.9 ~ 123 658 ~ 890
M30 × 2.0 137 ~ 185 990 ~ 1338 182 ~ 248 1314 ~ 1795
M36 × 3.0 192 ~ 260 1389 ~ 1879 262 ~ 354 1893 ~ 2561
1-10
--- Page 5 ---
2) INSTALLATION
After assembling mast components totally without piping connections, install mast assembly to the
equipment.
ö Installation procedure for each of mast component is the reverse of the removal procedure.
(1) Mast mounting pin
Η Check the mast mounting pins for wear, then install pins into the mast support bracket.
Θ Jack up the machine so that the front is raised and then using an overhead hoist assemble outer
mast to frame.
Ι Tighten mounting socket bolts to frame.
ÂTightening torque : 35.1~47.5 kgf·m (254~344 lbf·ft)
(2) Tilt cylinder pin
Hold the mast with a crane, operate the tilt control lever and align the holes, then knock the pin.
(3) Lift cylinder installation and adjustment
Η Assemble the lift cylinder inside the outer
mast, then tighten the stopper bolt. If the
cylinder assembly has been replaced,
adjust as follows so that the left and right
cylinders are synchronized at the maxi-
mum lifting height.
ΘAssemble the cylinder rod to the inner
mast, and check the left-to-right play of
the mast at the maximum lifting height.
ö If play is to LEFT, install adjustment shim
to LEFT cylinder.
öIf play is to RIGHT, install adjustment
D503RE03
shim to RIGHT cylinder.
ÂShim thickness : 1.0 mm (0.04 in)
2-6
--- Page 6 ---
SECTION 3 POWER TRAIN SYSTEM
Group 1 Structure and operation ------------------------------------------------------------------------------------ 3-1
Group 2 Inspection and troubleshooting ------------------------------------------------------------------------ 3-13
Group 3 Disassembly and assembly ------------------------------------------------------------------------------ 3-21
--- Page 7 ---
5. DRIVE AXLE
1) STRUCTURE
1 2 3 4 5 6 7 8 9 10 11 12 13 14
35D7ETA08
1 Sun gear 6 Hub assy 11 Pinion shaft
2 Planetary gear 7 Disk brake 12 Spider
3 Inner gear 8 Drive shaft 13 Differential pinion gear
4 Inner gear carrier 9 Differential carrier assy 14 Differential side gear
5 Tapered bearing 10 Ring gear
2) OPERATION
Drive axle which consists of differential carrier assembly (9), drive shaft (8) and hub assembly (6)
transmits the drive force from transmission to drive wheel.
Pinion shaft (11) is connected to transmission output shaft and spline.
The power of transmission is transmitted to differential which consists of pinion shaft (11) and ring
gear (10) and the differential rotates the drive shaft.
The differential transmits the drive force from transmission to wheels and one wheel's rotation
speed is differ from the other.
The differential consists of 4 pinions (13) , 2 side gears (14) and spider and the engagement
between 4 pinions (13) and side gear (14) makes a right angle.
Side gear (14) and drive shaft (8) are connected with spline and the drive shaft (8) consists of
planetary gear (2), inner gear (3), wheel hub (6) and drive wheels.
3-10
--- Page 8 ---
No Condition Possible causes Correction
5 Drive wheels do not rotate (1) Broken axle shaft.
a. Loose wheel bearings. Â Re-assemble wheel bearings.
b. Axle shaft too short. Â Replace drive shaft
c. Loose flange studs or nuts. Â Tighten studs or nuts
(2) D r i ve g e a r t e e t h h ave b e e n  Exchange damaged drive gear
damaged. set
(3) Side gear on differential damaged. Â Exchange damaged gear
(4) Differential pinion shaft or spider  Exchange damaged gear
broken
3-20
--- Page 9 ---
(2) Using different kinds of shims, adjust shim
thickness as measured by previous
equation.
Place shims at the bearing place.
Using a jig, assemble drive bearing so that
the outer race contact with the bearing
place.
35L7ADA03
(3) Heat the inner race of bearing to max
100°C and then assemble it to the pinion
shaft.
Also inner race should contact with
bearing place.
35L7ADA04
3-30
--- Page 10 ---
3. DISASSEMBLY OF TRANSMISSION
1) Pull torque converter (1) straight forward
and remove from the converter housing. 1
Remove six bolts (3) and flexible plate (1),
plate (2) from the torque converter.
2 3
35L7ADA22
2) Remove six socket bolts (3) and then gear
P.T.O input from the the torque converter. 4 6
5
D357TM02
3) Remove four bolts (9) and bolts (8), 7
washes, oil seal (10) from the housing
converter (7). 10
9
8 35L7ADA23
4) Remove plug (16) and o-ring, spring (18)
and ball (17) from the bearing plate.
5) Remove plug (13) and spring (12), valve
(14).
6) Remove plug (11).
35L7ADA24
3-40
--- Page 11 ---
11) Put clean transmission oil on each side of
the clutch plates and clutch discs. Install
four 2T clutch plates, three 4T clutch plates,
five clutch discs and one bending plate in
the cylinder with the following procedure.
(1) Install a clutch plate first, that has guide
shape on its outside diameter.
(2) Next, install a clutch disc that has teeth on
its inside diameter.
(3) Follow steps a and b again until all of four
the 2T clutch plates and discs are installed
in the cylinder.
(4) Install a 4T clutch plate, then install a
bending plate. In following procedure,
bending plate shape will be downward.
(5) Finaly, install a 4T cluch plate.
12) Use a screwdriver and install snap ring (57)
that check all of them in position in the 35L7ADA36
cylinder.
13) Install a three seal rings on the shaft.
ö Be carefully, Do not damage to the seal
rings on the counter shaft.
14) For the other side of the counter shaft
assembly, follow the procedure in steps 5
through 8.
15) Put clean transmission oil on each side of
the clutch plates and clutch discs. Install
four 2T clutch plates, three 4T clutch plates,
five clutch discs and one bending plate in
the cylinder with the following procedure.
(1) First, install a 4T cluch plate.
(2) Install a 4T clutch plate, then install a
bending plate. In following procedure,
bending plate shape will be downward.
(3) Follow steps a and b again until all of four
the 2T clutch plates and discs are installed
in the cylinder.
(4) Next, install a clutch disc that has teeth on
its inside diameter.
(5) Finally, Install a clutch plate first, that has
guide shape on its outside diameter.
3-50
--- Page 12 ---
4. INCHING PEDAL AND LINKAGE
The brake pedal serves to actuate the hydraulic brakes on the front axle. At the beginning of the
pedal stroke, the inching spool of the transmission control valve is actuated to shift the hydraulic
clutch to neutral and turn off the driving force. By treading the pedal further, the brake is applied.
e)
k
tro
gs
hin
Inc
e)
ok
m(
str
4m
e
~2
Idl
16
m(
4m
2~ 131~139mm(Pedal height)
T/M control valve
Inching spool
33mm(Default)
Inching link assy
Inching cable assy
35D9SBS04
4-3
--- Page 14 ---
SECTION 5 STEERING SYSTEM
GROUP 1 STRUCTURE AND FUNCTION
1. OUTLINE
Steering wheel
Steering cylinder
Steering unit Steering axle
Priority valve
T
L
P
R
P
Hyd
pump
Hydraulic tank
35DS7SE01
The steering system for this machine is composed of steering wheel assembly, steering unit, priority
valve steering cylinder, steering axle and piping. The steering force given to the steering wheel enters
the steering unit through the steering column. The required oil flow is sensed by the function of the
control section of the unit, and pressurized oil delivered from the hydraulic pump is fed to the steering
cylinder. The force produced by the steering cylinder moves the knuckle of steering tires through the
intermediate link.
The axle body is unit structure having steering knuckles installed to its both ends by means of kingpins.
Hub and wheel are mounted through bearing to spindle of knuckle.
5-1
--- Page 15 ---
Problem cause Remedy
Steering wheel turns unstea- ÂLockout loosening. ÂRetighten.
dily. ÂMetal spring deteriorated. ÂReplace.
Steering system makes abn- ÂGear backlash out of adjustment. ÂAdjust.
ormal sound or vibration. ÂLockout loosening. ÂRetighten.
ÂAir in oil circuit. ÂBleed air.
Abnormal sound heard when Valve
steering wheel is turned fully ÂFaulty. (Valve fails to open.) ÂAdjust valve set pressure and check
for specified oil pressure.
Piping
ÂPipe (from pump to power steering ÂRepair or replace.
cylinder) dented or clogged.
Piping makes abnormal Oil pump
sounds. ÂLack of oil. ÂAdd oil.
ÂOil inlet pipe sucks air. ÂRepair.
ÂInsufficient air bleeding. ÂBleed air completely.
Valve or valve unit makes Oil pump
abnormal sounds. ÂOil inlet pipe sucks air. ÂRepair or replace.
Valve
ÂFaulty. (Unbalance oil pressure) ÂAdjust valve set pressure and check
specified oil pressure.
Piping
ÂPipe (from pump to power steering) ÂRepair or replace.
dented or clogged.
ÂInsufficient air bleeding. ÂBleed air completely.
Insufficient or variable oil flow. ÂFlow control valve orifice clogged. ÂClean
Insufficient or variable dischar- Piping
ge pressure. ÂPipe (from tank to pipe) dented or ÂRepair or replace.
clogged.
Steering cylinder head ÂPacking foreign material. ÂReplace
leakage (Piston rod) ÂPiston rod damage. ÂGrind surface with oil stone.
ÂRod seal damage and distortion. ÂReplace
ÂChrome gilding damage. ÂGrind
Steering cylinder head thread ÂO-ring damage. ÂReplace
(A little bit leak is no problem)
Welding leakage ÂCylinder tube damage. ÂTube replace.
Rod ÂTube inside damage. ÂGrind surface with oil store.
ÂPiston seal damage and distortion ÂReplace
Piston rod bushing inner ÂBushing wear. ÂReplace
diameter excessive gap
5-11
--- Page 16 ---
(5) Press the springs together and push the
neutral position springs into place in the
sleeve.
5-77(2)
(6) Line up the springs and center them.
5-77(3)
(7) Guide the ring down over the sleeve.
ö The ring should be able to rotate free of
the springs.
5-77(4)
(8) Fit the cross pin into the spool / sleeve.
5-78(1)
5-21
--- Page 17 ---
2) DISASSEMBLY
ö Before disassembling steering cylinder, release oil in the cylinder first.
(1) Put wooden blocks against the cylinder tube, then hold in & vice.
(2) Remove the cover by hook a wrench in the notch of cylinder head and turn counter-clockwise.
(3) Remove the cylinder rod and piston from the tube.
(4) Check wear condition of the sealing parts (O-ring, oil seal, dust seal, U-packing, bush). If there
are some damage, replace with new parts.
3) CHECK AND INSPECTION mm (in)
Criteria
Check item Remedy
Standard size Repair limit
Clearance between 0.05~0.25 0.4
Replace piston seal
piston & cylinder tube (0.002~0.01) (0.02)
Clearance between 0.05~0.18 0.3
Replace bushing
cylinder rod & bushing (0.002~0.007) (0.01)
Seals, O-ring Damage Replace
Cylinder rod Dents Replace
Cylinder tube Biting Replace
4) ASSEMBLY
(1) Install a new piston seal around the groove on the
piston.
ö Be careful not to scratch the seal too much during
installation or it could not be seated properly.
D353SE27
(2) Install the rod seal to the position in the gland
applying a slight coat with grease prior to install.
D353SE28
5-31
--- Page 18 ---
3) WHEN THE TILT CONTROL LEVER IS IN THE FORWARD POSITION
9 8
12 13
2 B1 A2 B2 A3 B3 A4 B4
P T
Steering syetem
LS CF EF
Steering return line
4
G
P
Brake syetem
E/G T/M 1
Brake return line 11
10
35D7EHS04
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 (2) through the priority valve (4)
and then goes to the large chamber of tilt cylinder (8) by pushing the load check valve of the spool.
The oil at the small chamber of tilt cylinder (8) returns to hydraulic tank at the same time.
When this happens, the mast tilt forward.
6-4
--- Page 19 ---
4. LIFT CYLINDER
9 10 8 14 13 12 11 2 1 15 16 7 6 4, 5 3
D357HS12
1 Tube assy 7 Retaining ring 13 DU busing
2 Rod 8 Gland 14 O-ring
3 Piston 9 Dust wiper 15 Spacer
4 Piston seal 10 Rod seal 16 O-ring
5 Back up ring 11 O-ring
6 Wear ring 12 Guide
5. TILT CYLINDER
18 19 20, 21, 22 7, 8 3 11 12 5, 6 4 9, 10 2 1 13 16 14 15 17
23
D357HS13
1 Tube assy 9 O-ring 17 Nylon nut
2 Rod 10 Back up ring 18 Rod eye
3 Gland 11 Lock washer 19 DU bushing
4 DU bushing 12 O-ring 20 Hexagon bolt
5 Rod seal 13 Piston 21 Hexagon nut
6 Back up ring 14 Glyd ring 22 Spring washer
7 Dust wiper 15 Wear ring 23 O-ring
8 Snap ring 16 O-ring
6-14
--- Page 20 ---
(17) Remove seals from both bearing blocks
and discard.
PUMP 11
3) 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
--- Page 21 ---
5. TILT CYLINDER
1) STRUCTURE
12
11
3
5
6
7
8
2
24
22
23 24
21
18 1
19
20
17
16
15
13
14 ÂI.DÝO.DÝstroke :
4 90Ý102Ý220 mm
9 (3.5Ý4.0Ý8.7 in)
10 Â Rod O.D : 45 mm (1.8 in)
35DS7HS16
1 Tube assy 9 O-ring 17 Nylon nut
2 Rod 10 Back up ring 18 Rod eye
3 Gland 11 Lock washer 19 Spherical bearing
4 DU bushing 12 O-ring 20 Retaining ring
5 Rod seal 13 Piston 21 Hexagon bolt
6 Back up ring 14 Glyd ring 22 Hexagon nut
7 Dust wiper 15 Wear ring 23 Spring washer
8 Snap ring 16 O-ring 24 O-ring
6-34
--- Page 22 ---
·ELECTRICAL
ELECTRICAL CIRCUIT (3/4, FRAME 2 OF 2)
21FV-30030-00 3OF4
7-5-3
--- Page 23 ---
GROUP 3 COMPONENT SPECIFICATION
No Part name Qty Specification
12VÝ96 AHÝ2 EA
1 Battery 2 RC : 130 min
CCA : 630A
2 Working lamp 1 24V, 70W
3 License lamp 1 24V, 3WÝ2
24V, 25/10W (Stop/Tail)
4 Rear Combination lamp 2 24V, 21W (Turn)
24V, 10W (Back Up)
5 Head lamp 2 24V, 70W
6 Flasher lamp 2 24V, 25/10W
7 Glow relay 1 24V, 300A
8 Relay (4P) 3 24V, 20A
9 Relay (5P) 3 24V, 6A
10 Flasher Unit 1 85Ü10 CM, (21W + 21W) Ý 2 + 3W Ý2
11 Back buzzer 1 24V, 90Ü5 dB, 60Ü10 C/M
13 Horn 1 24V, MAX1.5A, 100 ~ 115 dB
Float indicator E 1/2 F
14 Fuel level sender 1 Resistance (ɮ) 105 32.5 5
0 0.5
Tolerance (ɮ) Ü2.5
5 0
15 Master switch 1 24V, 180A
Direction 4.5A, Tail 5A
16 Combination switch 1
Head 6A, Horn 4A
17 Brake switch 1 24V, 50W
18 Working lamp switch 1 24V, 8A
19 Hazard switch 1 24V, 8A
20 Start switch 1 24V, 30A
7-14
--- Page 24 ---
GROUP 2 OPERATIONAL CHECKS AND TROUBLESHOOTING
1. OPERATIONAL CHECKS
1) FORKS
(1) Measure thickness of root of forks and
check that it is more than specified value.
EX : ˶=1200 mm (47 in)
mm (in)
STD Fork assy Applicable model Standard Limit
S173896-02 35D-9S 50 (2.0) 45 (1.7) Thickness
F13710010 40D-9S 50 (2.0) 45 (1.7)
D507FK01
F18393603 45D-9S 50 (2.0) 45 (1.7)
F14710011 50D-9SA 60 (2.4) 54 (2.1)
2) Set forks in middle and measure out of
parallel and difference in height at the top of
forks.
Height
Model Fork length difference
35D/40D/45D-9S below 1500 3 mm
50D-9SA above 1500 6 mm
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.
ÂFront-to-rear clearance : Within 2.0 mm (0.08 in)