Kbd-30 Manual Taller

Workshop literature
Diesel Forklift Truck
KBD25
KBD30
KBD35
Header
Format of training manual

This training manual assumes that you have
completed service training and the correspond-
ing workshops, and have received supplementa-
ry training. This training manual is not suitable
for self-study if you do not attend the corre-
sponding workshops.
This training manual does not introduce the
truck structure in sequential order. In each chap-
ter, a single component of the truck is presented
as a standalone device.
The different chapters are based on the struc-
ture of the spare parts catalogue, which may be
different to the main catalogue.
The training guide is divided into chapters con-
sisting of a two-digit number, according to the
primary features of the function groups. The
main function groups are listed below. These
main function groups are further subdivided, with
these subdivisions used in the training manual.
Chapter Table of contents

00 Product information
10 Internal combustion engine
20 Running gear and drive chain
30 Chassis and bodywork
40 Driver’s compartment
60 Electrical system
70 Hydraulic system
80 Lifting system
90 Others
The introduction to the training manual is fol-

lowed by a complete table of contents. An index
is located at the end of the training manual.
Specialist
A qualified person is defined as a service engi-
neer or a person who fulfils the following require-
ments:
● A completed vocational qualification that de-
monstrably proves their professional exper-

tise. This proof should consist of a vocational
qualification or a similar document.
● Professional experience indicating that the
qualified person has gained practical experi-

ence of industrial trucks over a proven period
during their career During this time, this per-
son has become familiar with a wide range of
symptoms that require checks to be carried
60068042311 EN - 07/2021 - 01 I
Header
out, such as based on the results of a hazard

assessment or a daily inspection
● Recent professional involvement in the field of
the industrial truck test in question and an ap-
propriate further qualification are essential.
The qualified person must have experience of
carrying out the test in question or of carrying
out similar tests. Moreover, this person must
be aware of the latest technological develop-
ments regarding the industrial truck to be tes-
ted and the risk being assessed
II 60068042311 EN - 07/2021 - 01
Header
Symbols Used
The signal terms Danger, Warning, Caution,
Note and Environmental note are used in this NOTE
document as hazard warnings or for unusual in-
means that particular attention is drawn to the
formation that requires special identification: interrelationship between technical factors that
may not be evident even to a specialist.
DANGER
means that failure to comply involves risk to life ENVIRONMENT NOTE
and/or major damage to property can occur.
The instructions listed here must be strictly ob-
served in order to prevent damage to the envi-
WARNING ronment.
means that failure to comply involves risk of serious Additional signs and symbols are used to illus-
injury and/or major damage to property can occur. trate the hazard warnings. These are printed to
the left of the hazard warnings.
CAUTION
means that failure to comply involves risk of material
damage or destruction.
60068042311 EN - 07/2021 - 01 III

Header
Working on the electrical system

Working with the converters
DANGER
Due to the internal energy storage system in convert-
ers and control units, there may be dangerously high
voltages at the electrical connections in the event of a
fault, even after the battery male connector has been
disconnected.
Do not touch live contact points such as the positive
and negative connections of the power control units!
Before working on electrical power connections, al-
ways check the voltage between all contact points
and between the contact points and the truck chassis
using a suitable measuring device (capable of meas-
uring up to 1000 V/DC).
Discharge the intermediate circuit.
IV 60068042311 EN - 07/2021 - 01
Header
Safety guidelines
No changes, modifications or additions may be  Only use marked lifting points for towing or
made to the tractor without approval from the lifting. Attach the connections carefully. Check
manufacturer. that the pins/bolts provided are secure before
loading. Never stand close to drawbars, slings
DANGER or chains.
Incorrect inspection and maintenance procedures can  Before releasing hydraulic connections, en-
result in the malfunction of safety-critical components. sure that the system is depressurised.
Only carry out inspection and maintenance routines if  Do not allow hydraulic oil under pressure, for
you have been trained, and are authorised to do so.
example at a leak, to penetrate the skin. Med-
ical aid is required if such an injury occurs.
DANGER
Do not make modifications to the drive or braking pa-
WARNING
rameters without informing the tractor drivers.
Before working on or disconnecting any part of the
If modifications are made to the drive or braking pa- brake force booster system, the system must first be
rameters, then it is imperative that drivers are in- depressurised.
formed of such changes so that they are able to famil-
Do this by actuating the foot brake twenty times with
iarise themselves with the new operating characteris-
the key switch turned off.
tics before taking the tractor into service.
 Never wear rings, wrist watches, jewellery,

DANGER
loose or dangling items of clothing such as
The majority of accidents and injuries that occur in ties, torn clothing, scarves, unbuttoned jack-
workshops are caused by the failure to observe some ets or overalls with open zip fasteners that
basic rules of care and safety, and for this reason, in could get caught up in moving parts. Always
most cases they can be avoided. wear approved safety clothing.
Follow the safety guidelines below, anticipate poten-
tial hazards, and act with the necessary care and cau-  Never carry out maintenance or servicing op-
tion to reduce the risk to a minimum. erations on the tractor with anyone sat on the
An alert, cautious mechanic is a safe one. seat, unless that person is fully trained and in-
volved in the operation being carried out.
 Tighten the parking brake before repair work.  Never switch on the tractor from any position
other than the driver's seat.
 Switch off the key switch.
 The design of service steps or platforms used
 Disconnect the battery. for maintenance in the workshop or on site
 Secure the front and rear wheels with wheel must comply with current regulations.
chocks.  Label all controls to indicate a service or re-
 Before electrical maintenance work or checks, pair operation is being carried out.
raise the drive wheels from the ground and  Protective equipment, i.e. safety footwear, in-
secure the truck with wheel chocks. dustrial goggles, protective masks, protective
 Always wear protective equipment (industrial gloves etc. must be worn at all times when
goggles and gloves) when working on a bat- working with cleaning equipment that uses
tery. compressed air or steam.
 Always observe the required fire protection  Perform a functional check and trial run after
measures when working on batteries. every service.
 Always handle, charge and maintain batteries
according to the manufacturer's instructions Handling lubricants
supplied with the battery.
Always handle lubricants safely and as specified
 Always ensure that the lifting equipment used by the manufacturer.
has the required load capacity and is certified
Only store lubricants in approved containers at
accordingly. All blocks, jacks, chains etc. are
specified storage locations. As they could be
subject to regular checks and must only be
flammable, do not let them come in contact with
used for the purpose intended.
hot objects or naked flames.
60068042311 EN - 07/2021 - 01 V
Header
Clean the area surrounding the part in question

before lubrication, filter renewal or repairs in the ENVIRONMENT NOTE
hydraulic system.
Lubricants and compounds used during mainte-
Only use clean containers when replenishing nance procedures can be harmful to the environ-
fuels and lubricants. ment. Please observe the following:
● Follow the manufacturer's safety and disposal
instructions when using lubricants and clean-

ing compounds
● Avoid spilling lubricants. Remove any spillage
immediately with a suitable absorbent, and

dispose of as per local legislative require-
ments
● Always dispose of used or contaminated lubri-
cants as specified. Follow laws and regula-

tions
● Dispose of used parts, empty containers, fil-
ters etc. as per local legislative requirements
VI 60068042311 EN - 07/2021 - 01
Table of contents
00 Production information
Industrial truck documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1
Truck information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-1
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-2
Data sheet for KBD25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-3
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-9
Safety precautions for maintenance and repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-9
Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-10
Supply table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-11
Diesel fuel - Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-11
Engine coolant - specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-13

Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
General introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Danger, warning, caution and note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Engine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
Performance and specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6
Engine Performance Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8
Outside drawing of the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9
About the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Marking system of units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-13
Tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-15
Engine disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17
Engine assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-34
Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62
Failure Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-62
Water pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-63
Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-67
Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70
Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-71
Oil filter assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-79
Oil pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-82
60068042311 EN - 07/2021 - 01 VII

Table of contents
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-85

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-85
Fuel return hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-86
Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-87
Common rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-96
Fuel injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-103
Intake/exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111
How to Maintain Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-115
Turbocharger Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-117
Turbocharger Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-117
Turbocharger Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-119
Disassembly of EGR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-120
Assembly of EGR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-121
Intake manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-123
Exhaust manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-130
Intake stake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-134
Cylinder block/cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-136
Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-137
Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-139
Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140
Rocker arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-145
Tappet and push rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-153
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-162
Timing gear case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-165
Flywheel housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-168
Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-170
Cylinder head cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-171
Idle gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-178
Lifting hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-184
Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-186
Electric Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-186
Circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-187
Switches and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-192
Wire harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-197
Electronic Control Unit (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-197
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-201
Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-203
Other/drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-205
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-206
Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-212
Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-215
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-217
VIII 60068042311 EN - 07/2021 - 01

Table of contents
Crankshaft pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-219

Others . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-221
Description of diagnostic software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-223
Description of diagnostic software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-223
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-234

Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-234
Cooling system engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-235

Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-235
Particle filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-236

Exhaust pipe and gas exhaust aftertreatment device installation . . . . . . . . . . . . . . . . 10-236
20 Running gear and drive train

Torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
Hydraulic transmission gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
Main technical parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-2
Hydraulic torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3
Feed pump assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-4
Inching valve assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-5
Clutch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-6
Differential assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-8
Electrohydraulic control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-9
Working principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10
Transmission principle of gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10
Power flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-11
Oil line schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-12
Gearbox disassembly procedure and precautions (same for manual and electronic
versions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-15
Drain the oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-15
Remove the differential assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-15
Remove the torque converter assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-16
Removing the oil pump assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-16
Remove the torque converter housing, 3 O-rings and paper gaskets . . . . . . . . . . . . . 20-16
Remove the control valve assembly, 2 O-rings and paper gaskets . . . . . . . . . . . . . . 20-17
Remove the inching valve assembly and paper gasket . . . . . . . . . . . . . . . . . . . . . . . 20-17
Remove the oil filter assembly, paper gasket and dipstick . . . . . . . . . . . . . . . . . . . . . 20-17
Remove the clutch assembly and idler shaft assembly . . . . . . . . . . . . . . . . . . . . . . . 20-18
Remove the bearing caps and adjustment shims at both ends . . . . . . . . . . . . . . . . . . 20-19
Remove the support piece and output shaft assembly . . . . . . . . . . . . . . . . . . . . . . . . 20-19
Remove the output gear and idler gear from the torque converter housing . . . . . . . . . 20-20
Disassemble the differential assembly and ring gear . . . . . . . . . . . . . . . . . . . . . . . . . 20-20
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Removing the clutch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21

Removing output shaft combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21
Gearbox assembly procedure and precautions (same for manual and electric
versions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22
Output gear and bearing combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22
Idler and bearing combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-22
Idler shaft and bearing combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23
Gear shaft and bearing combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-23
Torque converter housing and oil pump combination . . . . . . . . . . . . . . . . . . . . . . . . . 20-23
Piston assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
Output shaft combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-25
Primary oil filter combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-26
Differential assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-26
Clutch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-27
Machine assembly step 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-28
Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-34
Pressure inspection ports for gearbox repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-34
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-35
Drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-36

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-36
Main technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-37
Structure and working principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-37
Installation and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-38
Precautions for use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-39
Bleeding air from the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-39
Procedure for bleeding the air (this is a two-person job that requires a coordinated
effort) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40
Disassembly and assembly sequence and table of alarms and units . . . . . . . . . . . . . 20-41
Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42
Hydraulic steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42
Steering unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42
Operating principle of the steering gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-43
Steering gear parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-47
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Precautions for steering device installation and usage . . . . . . . . . . . . . . . . . . . . . . . . 20-47

Steering gear troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-48
Steering axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-49
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-49
Key points of maintenance and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50
Steering axle structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-52
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-53
Brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-55

Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-55
Service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-56
Service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-56
Brake fluid cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-58
The brake master cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-58
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60
Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-60

Basic structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
Counterweight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
DPF light and switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
Design and labbeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-3

Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-3
Load centre distance and load capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
Capacity chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-4
Location of decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-6
40 Driver's compartment
Attachment parts interior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
Bonnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-1
Seat (seat belt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-2
Display-operating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3

Display unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3
Operating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4

Overview of the driver’s compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4
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60 Electrics
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-2
Diagram of main harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-2
Electrical system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-9

Instrument . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-9
Technical parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-9
Plug connector terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-10
Control compartment part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-11
Control compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-11
Port definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-12
Interior schematic diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-13
Tail light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-15
Reversing lights/beeper circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-16
Direction control circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-17
Foot brake indicator/warning circuit (you must apply the foot brake when exiting the
truck, otherwise the warning horn will continuously sound) . . . . . . . . . . . . . . . . . . 60-17
Horn circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-18
ECU control power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-19
Start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-20
Fuel level circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-21
Indicator light circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-21
Lifting circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-22
Lowering circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-22
Display unit circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-23
Lighting circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-23
Brake light circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-24
Turn signal light circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-24
Preheat circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-25
Starter batteries and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-26

Battery part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-26
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-27
Battery storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-27
Installing and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-27
Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-28
Charging precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-28
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-29
Charging methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-29
Fuse wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-30
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70 Hydraulics
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-1
Basic information about the hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-1
Punp-motor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-2

Model number definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-2
Gear pump performance parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-3
Working principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-3
Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-4
Directional control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-7

Directional control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-7
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-7
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-8
About the functions of main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-9
Hydraulic line direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-13
Schematic diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-14
Flow divider valve structure and principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-15
Lifting function (lifting procedure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-17
Lifting function （Load-keeping procedure） . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-19
Lowering function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-21
Front tilt function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-23
Rear tilt function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-25
Auxiliary function (retraction process) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-27
Auxiliary function (extension procedure) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-29
Pressure control function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-31
G-point pressure point signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-33
Oil intake flow rate control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-35
Bypass oil line (prevents speed loss) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-37
Electromagnetic parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-39
Precautions for installation, commissioning and running . . . . . . . . . . . . . . . . . . . . . . 70-40
Transport and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-41
Adjusting the directional control valve pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-41
Auxiliary safety pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-42
Cylinder leak inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-42
Flow control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-44
60068042311 EN - 07/2021 - 01 XIII

Table of contents
80 Lifting system
Lifting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-1
Mast specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-1
Duplex lift mast high lift cylinder repair pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-4
Triplex lift mast high lift cylinder repair pack (side cylinder) . . . . . . . . . . . . . . . . . . . . 80-7
Triplex lift mast high lift cylinder repair pack (middle cylinder) . . . . . . . . . . . . . . . . . . 80-9
Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-11
Lubricating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-11
Chain lubrication prior to factory release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-11
Reapplying lubrication (during operation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-11
Cleaning chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-12
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-12
Inspection plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-12
Control standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-14
Running test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-16
Running test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-16
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-16
Replacing the chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-17
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-18
Chain adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-18
Leaf chain maintenance and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-19
Replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-19
Specific procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80-19
XIV 60068042311 EN - 07/2021 - 01

Production information 00
Industrial truck documentation

Truck information
The KBD25-35 forklift is a front axle-driven, in-
ternal combustion counterbalanced forklift truck
that uses an advanced transmission, a wide visi-
bility mast system, full hydraulic steering mecha-
nism, automatic booster brake and other ad-
vanced technologies and equipment. It offers su-
perior performance, convenient operation, a
wide field of vision, flexible steering, reliable
braking, low noise and an attractive appearance.
It is suitable for loading and unloading goods in
various places, such as freight yards, stations,
ports, airports, factories and warehouses. It is
the ideal machine for mechanised loading and
unloading.
60068042311 EN - 07/2021 - 01 00-1

Dimensions
00-2 60068042311 EN - 07/2021 - 01

Data sheet for KBD25
NOTE
This VDI data sheet specifies only the technical

values of the truck version with standard equip-
ment. Different tyres, lift masts, additional units
etc. may produce different values.
Characteristics
Manufacturer BAOLI
Model KBD25
Power type：Electric-Diesel-Petrol-LPG-Network Power
Diesel
(Electric)
Operation Type:Hand-stand on-Driver seated Seated
Load Capacity Q (kg) 2500
Load centre of gravity distance c (mm) 500
Axle centre to fork face x (mm) 479
Wheel Base y (mm) 1700
Weights
Service Weight Kg 4050
Axle loading, laden front/rear Kg 5820/730
Axle loading, unladen front/rear Kg 1530/2520
Wheels, chassis frame
Tyres:SE-Super elastic PN-Pneumatic SE
Front Tyres Size 28x9–15/14PR
Rear Tyres Size 6.50-10/10PR
Front Track Width b10 (mm) 1000
Rear Track Width b11 (mm) 970
Dimension and overall sizes
Mast lift, forward/backward α/β 6°/12°
Mast Minimum Overall Height h1 (mm) 2080
Free lift h2 [(mm) 140
Lift height h3 (mm) 3000
Mast Maximum Overall Height h4 (mm) 4040
Overhead Guard Height h6 (mm) 2110
Seat Height h7 (mm) 1165
Drawbar Height h10 (mm) 300
Overall Length I1 (mm) 3730
Length to Face of Forks I2 (mm) 2660
Overall Width b1 (mm) 1225
Fork Arm Dimensions s/e/l (mm) 40/122/1070
Fork Carriage in Compliance with ISO 2328 Class/Form
A
A,B
Fork Carriage Width b3 (mm) 1040
Ground Clearance below Mast(laden) m1 (mm) 135
Ground Clearance at Centre of Wheelbase(laden) m2 (mm) 140
Working aisle width with pallet 1000 x 1200 cross-
Ast mm) 4119
ways****
Working aisle width with pallet 800 x 1200 crossways**** Ast mm) 4319
60068042311 EN - 07/2021 - 01 00-3

Turning Radius Wa (mm) 2440

Turning Point Minimum Distance from the Truck Center
b13 (mm) 810
Line
Performance data
Driving speed (with/without load) km/h 18/18
Lifting speed (with/without load) m/s 0.57/0.59
Lowering speed (with/without load) m/s 0.48/0.40
Drawbar Pull Tractive Effort (at 2km/h) with/without load KN 19/16
Gradeability (at 2km/h) laden/unladen % 20/20
Service Brake Mechanical/Hydraulic
Engine
Engine Type DOOSAN D24
Engine Power in compliance with ISO 1585 kW 36.4
Rated Number of Revolutions rpm/min 2400
Cylinder Number/Displacement cm3 4/2400
On-board voltage V 12
Others
Hydraulic torque convert-
Drive Control Type
er
Volume fuel tank L 62
Towing coupling, type DIN 15170 PIN
00-4 60068042311 EN - 07/2021 - 01


Characteristics
Manufacturer BAOLI
Model KBD30
Diesel
(Electric)
Weights
Tyres:SE-Super elastic PN-Pneumatic PN
Front Tyres Size 28X9–15/14PR
Rear Tyres Size 6.50-10/10PR
Free lift h2 (mm) 145
A
A,B
Working aisle width with pallet 1000 x 1200 crossways**** Ast (mm) 4144
b13 (mm) 810
Line
Performance data
60068042311 EN - 07/2021 - 01 00-5


Engine
Others
Drive Control Type
er
00-6 60068042311 EN - 07/2021 - 01


Characteristics
Manufacturer BAOLI
Model KBD35
Diesel
(Electric)
Weights
Tyres:SE-Super elastic PN-Pneumatic PN
Front Tyres Size 28X9–15–14PR
Rear Tyres Size 6.50-10-10PR
Free lift h2 (mm) 150
A
A,B
b13 (mm) 810
Line
Performance data
60068042311 EN - 07/2021 - 01 00-7


Engine
Others
Drive Control Type
er
00-8 60068042311 EN - 07/2021 - 01

Service
Safety precautions for mainte-
nance and repair
• Repair and maintenance work may only be
performed by trained service personnel (profes-
sionals) in accordance with the training manual.
• When lifting parts or assemblies, make sure all
slings, chains, or cables are correctly fastened,
and that the load being lifted is balanced. Make
sure the crane, cables, and chains have the ca-
pacity to support the weight of the load.
• Do not lift heavy parts by hand; use a lifting
mechanism.
• Wear safety glasses.
• NOTE: before servicing internal combustion lift
trucks, be sure to disconnect the battery plug
and the battery wiring cable.
• Always use correct blocks to prevent the unit
from rolling or falling.
• Keep parts clean and the working area clean
and orderly.
• Only use parts and oils approved by the manu-
facturer when making repairs. Replacement
parts must meet or exceed the specifications of
the original equipment manufacturer. For oil
products, refer to the table below.
• Make sure all nuts, bolts, snap rings and other
fastening devices are removed before disassem-
bling parts. When installing the main compo-
nents, the bolts must be tightened in accordance
with the regulations. For details, refer to the
"Tightening Torques" section.
• Always fasten a DO NOT OPERATE tag to the
controls of the unit when making repairs, or if the
unit needs repairs.
• Be sure to follow the DANGER, WARNING and
CAUTION notes in the instructions.
• Diesel fuel is flammable. Be sure to follow the
necessary safety precautions when handling
these fuels (gases) and when operating on the
fuel (gas) system.
• Batteries may generate a large amount of flam-
mable gas when they are being charged. Open
flames and sparks are strictly prohibited in the
charging area. Make sure the area is well venti-
lated.
• Perform a functional test on the truck after all
repair and maintenance work is completed.
60068042311 EN - 07/2021 - 01 00-9

Service
Handling consumables
ENVIRONMENT NOTE
Consumables and cleaning agents used during

repair and maintenance operations may be
harmful to the environment.
Observe the following precautions:
● Always dispose of consumables in accord-
ance with the manufacturer's instructions.

● Use only suitable containers to transport and
store lubricants, and store them in approved

storage areas.
● Flammable lubricants should be kept away
from hot objects and open flames.

● Only use clean containers to top up consuma-
bles.
● Remove any spilled fluid immediately with a
suitable binder. Dispose of leaking liquid in

accordance with applicable regulations.
● Dispose of used or contaminated consuma-
bles in accordance with applicable regula-

tions.
● Before performing lubrication, changing filters
or servicing the hydraulic system, clean the

area around the relevant parts.
● Cover any plastic panels when using a chain
spray, as it is difficult to remove from plastic

panels.
Tightening torque
Tightening torque Tightening torque
Parts Bolt/Nut
(±10% N.m) (±10% Kg.m)
Lift mast support M16x1.5x70 196 20
Front axle and gearbox
M12x1.25x35 78.5 8
fastening
Engine and gearbox fas-
M10x50 44 4.5
tening
Engine and undercar- Just connect the spring
M10x45 /
riage fastening and tighten
Front axle support M16x1.5x70 196 20
Rear axle fastening M16x50 196 20
Front tyre fastening M20x1.5 525 53.6
Rear tyre fastening M14x1.5 181 18.5
Flexible connections
Safety awning fastening M10x100 with steel sleeves: just /
tighten
Counterweight fastening M30x130 1315 134.2
00-10 60068042311 EN - 07/2021 - 01

Service
Supply table
Recommended Quanti-
Unit Operating material Specifications
ty
Engine 7.5L Engine oil API CJ-4 SAE15W-40
Hydraulic transmission
9L Transmission oil Dexron Ⅲ/ Mobile ATF
gear
38L for mast below
4500mm mast ≥-5℃:L-HM46
Hydraulic system Hydraulic oil ≥-20℃:L-HV32(For cold
40L for mast exceeding storage use)
4500mm mast
Braking system 0.3L Brake fluid DOT-3
Bearings, lubricating
0.05KG Lubricating grease NLGL 2 lithium grease
grease fittings
-15℃~+49℃: GL-5
85W/90
Drive axle 6L Gear oil -25℃~+49℃: GL-5
80W/90
(For cold storage use)
Radiator water tank:
Coolant/water See section "Engine cool-
Cooling system 11L
ant-Specifications"
Reservoir box: 0.9L Coolant/water
2.0-2.5T:20L See section "Diesel fuel-
Fuel Diesel
3.5T:23L Specifications"
WARNING
Use of products with specifications lower than those
set out in the table could cause damage to the truck
not covered by the warranty.
Diesel fuel - Specifications

Fuel quality is an important factors in satisfy
standards for engine performance, engine life-
time, and emissions.
CAUTION
Use clean, specified, and qualified fuel only.

Using irregular or unspecified fuel may cause critical
damage and faults to the engine.
When fuel needs to be added, be sure to add fuel with
the engine stopped.
Fuel Standards
The design layout is done for fuel fulfilling all re-
quirements of at least one of the following stand-
ards.
60068042311 EN - 07/2021 - 01 00-11

Service
● EN590: 2013/AC:2014
● ASTM D975C-15 Grades 1D or 2D, with the
restrictions regarding paraffinic fuels and
FAAE as indicated below
● JIS K2204:2007 with a lubricity (HFRR test,
per test method ISO12156-1)≤520μm and
acc. to the Japanese legal regulations with
the restrictions regarding paraffinic fuels as
indicated below. This includes up to 5% of
FAME acc. to JIS K2390:2008.
● GB252:2015 and GB19147:2013
● IS1460 2005 Amm. 10 BSⅢ or BSⅣ
● ANP69/2014
● GOST R32511-2013 except it’s arctic classes
3&4
Paraffinic fuels
Paraffinic material (synthetically produced hy-
drocarbons, hydro-treated vegetable oils and
fats) hold promise as a blend component in con-
ventional diesel fuel. The use of paraffinic blen-
ded fuel is covered by this data sheet, provided
that the final fuel fulfils an allowed fuel standard
as indicated by this data sheet.
NOTE
ASTM D975 and JIS K2204 specifications do

not exclude neat or pure paraffinic fuels. Neat
paraffinic material characteristics can differ sub-
stantially from fuels described in this data sheet
and therefore additional validation for such ma-
terial is necessary.
Fatty acid alkyl ester (FAAE) as blend compo-
nent
Due to market availability, validation of such
blend components has only been done with fatty
acid methyl esters (FAME). Fuels according to
ASTM D975 could contain other nonvalidated
FAAEs according to ASTM D6751.
To maintain the optimum engine performance,
refer to the following recommended fuel table to
select the appropriate fuel.
Fuel Components Standard

Specific gravity (kg/lit) 0.820 ~ 0.845
Flash point (°C) 40 or higher
Kinematic viscosity (40 °C) (cSt) 1.9 ~ 5.5
Sulfur content (wtppm) 15 or less
Cloud point (°C) -
Pour point (°C) 17.5 or less
Low-temperature filter clogging temperature (°C) 16 or less
Color (ASTM) 2.5 or less
Carbon residue (10 %) Distillation residue (wt) (%) 0.15 or less
00-12 60068042311 EN - 07/2021 - 01

Service
Total acid number (mg KOH/g) 0.40 or less

Copper corrosion (100 °C, 3 hours) 1 or less
Ash content (mass %) 0.01 or less
Water and deposits (vol. %) 0.02 or less
Cetane number 45 or higher
50% distillation point -
Distillation test temperature
90 % distillation point 360 or less
NOTE
High sulphur content in Doosan diesel engines

can be operated with fuels whose sulphur con-
tent is max. 15wtppm.
Engine coolant - specifications

Coolant plays an important role in preventing CAUTION
overheating and freezing of the engine. Howev-
er, as the engine is used over time, the anticor- The tap water standards are intended for reference
rosive and anti-rust performance of the coolant only. Do not use them as absolute standards.
diminishes. The state of the coolant must be If the water quality is suspect, avoid using tap water
maintained through daily inspections and re- and use distilled water instead, if possible.
placed regularly.
The mixture ratio for engine coolant should be The coolant must be inspected regularly in order
45 ~ 50% antifreeze included (Note: If anti-cor- to maintain the concentration of antifreeze and
rosive agent is not contained, the DCA should additives.
be added 3 ~ 5%) and 3 to 5% of an additive
(DCA4) for preventing corrosion. CAUTION
Use coolant which satisfies the standards below: By maintaining the coolant at the recommended mix-
ture ratio , you can effectively prevent corrosion in the
Specification Specification number engine and maintain long-term optimal engine per-
ASTM D3306, D6210 formance. Using contaminated water or an unspeci-
fied antifreeze or additive can cause serious faults in
JIS K2234 the cooling system.
SAE J1034
Use distilled water or tap water. Natural water Amount of Antifreeze in Winter
such as river water or underground water (hard
water) contains a significant amount of minerals Coolant freezing point according to anti-freezing
which form deposits in the cooling system and ratio:
degrade the cooling performance, so make sure
to use tap water which satisfies the following Freezing point
Coolant (%) Antifreeze (%)
standards. (°C)
85 15 Above -10
80 20 -10
NOTE
73 27 -15
Standards for usable tap water: 67 33 -20
● Inorganic chloride: < 40 ppm(Parts Per Mil- 60 40 -25
lion) 56 44 -30
● Sulphate: < 50 ppm(Parts Per Million)
50 50 -35
● Hardness: < 9.5 °d.H
● Solids : < 340 ppm(Parts Per Million)
● Acidity : 5.5 ~ 9.0
60068042311 EN - 07/2021 - 01 00-13

Service
00-14 60068042311 EN - 07/2021 - 01

Internal combustion engine 10
Diesel engine
General introduction
General Information
This Operation and Maintenance Manual pro- The maintenance methods stated in this Opera-
vides the most efficient methods for engine tion and Maintenance Manual are the most effi-
maintenance as well as quick, efficient methods cient and safest work procedures. Some work
to determine the cause of engine faults to en- procedures require special tools. For questions
sure that any actions taken by professionally about genuine parts and special tools, please
certified maintenance technicians are done in contact us.
the most efficient and efficient way possible. If
This Operation and Maintenance Manual in-
maintenance is performed by unskilled techni-
cludes 'Danger,' 'Warning,' and 'Caution' in order
cians, or maintenance without the specified tools
to reduce possible injuries and engine faults
and facilities, serious bodily injury or critical
which may occur while performing maintenance.
faults in engine performance may occur.
If workers do not follow the instructions, critical
Regular inspection and maintenance are re- faults in engine performance and operation or
quired to maintain long-term optimal engine con- serious bodily injury may occurred. 'Danger,'
ditions and best performance. In the event that a 'Warning,' and 'Caution' instructions must be fol-
part must be replaced, only genuine parts as de- lowed. However, we inform you that it is not pos-
fined by the parts the list (PARTS BOOK) should sible to describe all possible and unexpected
be used. Doosan shall not be held liable for any dangers which may arise while performing en-
critical damage or faults which may be caused gine maintenance.
by the use of unauthorized or remanufactured
parts.
Danger, warning, caution and note

General Information CAUTION
This Operation & Maintenance manual divides Workers must observe this instruction since failing to
maintenance operations such as performing en- do so may cause critical faults which can have impact
gine checks, troubleshooting, or diagnosing on the engine performance and operation.
faults into three categories, "Danger," "Warning,"
and "Caution." In addition, Note) is used to pro- Note) Indicates additional description, informa-
vide additional descriptions and information re- tion, and references for workers' easy under-
quired for maintenance technicians to success- standing.
fully operate our engines. The recommended re-
pair methods and 'Danger,' 'Warning,' and 'Cau-
tion' can enhance the degree of completion of General Instructions
engine maintenance and prevent bodily injury
1. In order to maintain the best long term per-
which may occur to workers. However, this man-
formance and safety, please read and under-
ual cannot predict all possible risks.
stand this manual and execute routine inspec-
tions and regular inspections.
DANGER
2. We have divided the content of this manual
Workers must observe instructions, otherwise fatal or into causes of bodily injury and damage to as-
serious injuries to workers and other persons may oc-
cur.
sets and causes of pollution.
WARNING
Workers must follow this instruction as failing to do so
may result in the death or serious bodily harm of
workers or others.
60068042311 EN - 07/2021 - 01 10-1

Diesel engine
WARNING 3. Use an engine oil drain container that is large

enough to prevent the overflow of engine oil
When a safety accident, such as skin contact with while draining engine oil.
corrosive acids or fuel, burns with hot oil, exposure of
eyes to fuel or antifreeze, occurs while starting, in- 4. Open the engine coolant cap after fully cool-
specting, or repairing an engine, see a doctor imme- ing the engine to exchange or replenish coolant.
diately.
WARNING
Cautions for Starting the Engine If the coolant cap is opened while the engine is still
hot, hot water will spurt out and may cause burns.
1. Before starting the engine, please read this Open the engine coolant cap after fully cooling the
manual carefully and fully understand 'Danger,' engine.
'Warning,' and 'Caution'. If you cannot fully un-
derstand it or have any question, please contact
us. 5. Fuel is highly flammable. Smoking or use of
fire around an engine may cause fire.
2. For safety reasons, attach "Warning" signs
around engines in operation to keep people oth- WARNING
er than workers from accessing the engines. Let
engine operators know that they are responsible Only refuel when the engine is stopped.
for the safety of the engine room.
3. Only authorized people may start and operate 6. Mark and separately manage the containers
engines. Unauthorized people should not be al- for storing coolant from beverage containers for
lowed to handle engines. avoiding confusion. See a doctor immediately in
4. Do not access running or rotating parts while case of drinking coolant.
the engine is in operation. 7. Follow the instructions provided by the battery
manufacturer when checking or handling batter-
5. Be careful not to touch or contact the engine
ies.
during operation since it becomes hot during op-
eration.
WARNING
6. Exhaust gas is poisonous. Fully ventilate be-
fore starting engine. If the space is airtight, en- Battery fluid is corrosive and dangerous because of
sure that it is well ventilated. its explosiveness and toxicity. Therefore, it should on-
ly be handled by a skilled technician who specializes
in battery fluid.
Cautions for Inspection and Repair
1. Inspection and repair of engine should be per- 8. Only certified professional technicians should
formed only when the engine is stopped. Other- repair and maintain engines.
wise, burns or safety accidents may occur, so do
9. Only appropriate tools should be used. If the
not perform inspection or repair while the engine
jaws of a wrench are worn out, the wrench might
is running.
slip during use, causing safety accidents.
2. If it is absolutely necessary to perform inspec-
10. Do not allow other persons to stay or pass
tion or repair on the operating engine, do not get
under an engine when lifting the engine with a
close to the rotating parts.
crane. Before lifting the engine, ensure that
there is no one around the engine and reserve
DANGER enough safety space.
When accessories such as necklaces, rings, watches, 11. Before inspecting or replacing the electrical
or gloves become stuck in rotating parts while the en-
apparatus, disconnect the battery ground wire
gine is running, serious bodily injury may occur.
first. Connect the battery ground wire after com-
pleting all required work for checking or replac-
WARNING ing the electrical apparatus in order to prevent a
short circuit.
Do not exchange or disassemble a pipe or horse
(from the engine fuel circuit, engine oil circuit, coolant 12. Before performing electric welding works,
circuit, or compressed air circuit) while the engine is turn off engine, block the power supply to the
running. The leaked liquid may cause bodily injuries. engine, and remove the wire harness connector
connected to the engine control unit (ECU).
10-2 60068042311 EN - 07/2021 - 01

Diesel engine
13. Do not give any electric or mechanical Other Safety Instructions and Environmen-
shocks or perform welding works on the electri- tal Pollution
cal apparatus or the ECU.
Observe the following instructions to protect
workers from danger and to prevent the environ-
General Repair
mental pollution while performing engine repairs.
1.Wait until the engine is properly cooled down 1.Good ventilation and low humidity should be
before starting work, since you may get burned maintained in the work space.
by the heated engine.
2.The workspace should be clean, in good or-
Before performing fuel line work, check the com- der, and no flammables are allowed in the work-
mon rail pressure and engine temperature by shop.
using the failure diagnosis device.
3.Smoking is strictly forbidden in the workshop.
2.Disconnect the battery ground wire from to
prevent damage of wires and sensors caused by 4.Workers should wear working clothes, protec-
a short circuit. tive goggles, and safety shoes.
3.Engine oil and coolant may damage paint and 5.Workers are not allowed to wear accessories
should be stored in a separate container and such as necklaces, rings, watches, and earrings.
marked for safe management. 6.Start the engine in a well-ventilated space and
4.Store the disassembled parts in a specified fully ventilate the space before starting engine to
space to avoid damage or pollution. prevent carbon monoxide poisoning.
5.Use specified and special tools for efficient 7.Wait until the engine is properly cooled down
and safe repair. before starting work, since you may get burned
by the heated engine.
6.If parts need to be replaced, use only genuine
parts for replacement. Using unauthorized or re- 8.Do NOT work on rotating or running parts
manufactured parts may cause critical damage once the engine has been started.
and faults in engine performance. 9.Discard oil according to the regulations set
7.Replace parts such as cotter pins, gaskets, O- forth by the relevant authorities.
rings, seal rings, oil seals, and washers with new 10.If engine oil or fuel leaks on the floor or is im-
ones during repairs. Reuse of parts may be the properly discharged, serious environmental pol-
cause of engine faults and engine may not oper- lution of sea, river or underground water may oc-
ate properly. cur.
8.Group and store disassembled parts in disas- 11.Discard the undiluted anticorrosive agent, an-
sembling order. The strength, shape, and screw tifreeze, filter elements, and cartridges as spe-
torque of bolts and nuts are different according cial wastes.
to their assembly position. Please divide and
store them accordingly to these characteristics. 12. Discard coolant and special waste according
to the regulations of the appropriate authorities.
9.Clean disassembled parts to remove foreign
substances before inspecting or reassembling
WARNING
parts. Use compressed air to clean the oil holes
or holes. Failure to observe the regulations of the relevant au-
thorities violates environmental pollution regulations
10.Thinly spread oil or grease on rotating parts and may be subject to legal penalties.
or parts requiring lubrication, before assembling
them.
11.If required, use a specified adhesive to as- Use of Genuine Parts
semble gaskets to prevent water or oil from leak-
An engine consists of many parts which are me-
ing.
chanically harmonized. To prevent engine faults
12.Assemble bolts and nuts with the specified in advance and use engines with best perform-
tightening torque. ance for a long period, maintenance and re-
placement of expendable parts should be con-
13.After completing repairs, conduct a final in-
ducted regularly.
spection and perform a test operation to check if
all works have been successfully completed. Use of genuine parts is recommended. Using
unauthorized or remanufactured parts may
60068042311 EN - 07/2021 - 01 10-3

Diesel engine
cause critical damage and faults to engine for
which Doosan shall not be held liable.
Engine maintenance
Prevention of Damage and Abrasion CAUTION
Using an engine for any purposes other than the Immediately replenish engine oil when the engine oil
designed purpose may cause critical faults in level is below the lower limit of the engine oil gauge.
engine performance for which Doosan shall not
be held liable. For details concerning the usage
and purpose of the engine, please direct ques- 8. If there are gauges for battery, oil pressure
tions to our Sales Team. Do not adjust, convert, and coolant and temperature, check if they indi-
or change the ECU without our authorization. cate a normal status.
If a problem is found in an engine, figure out and 9. Do not operate engine without coolant.
solve the cause to prevent the critical faults in
advance. CAUTION
Use of genuine parts is recommended. Using Always use coolant mixed with antifreeze. If coolant
unauthorized or remanufactured parts may without antifreeze is used, the coolant may freeze
causing the coolant passage in the cylinder block to
cause critical damage and faults to engine for
freeze and damaging the engine.
which Doosan shall not be held liable. Consider
the following while managing engines.
1. Use clean, specified, and qualified fuel only. Prevention of Pollution
Use fuel recommended in this Operation and
Maintenance Manual. Consider the following to manage engine without
causing environmental pollution.
CAUTION 1. Discharge oil and coolant using collection
containers.
Using inappropriate or unspecified fuel may cause
critical damage and faults in engine performance. 2. Discard oil and coolant according to the regu-
lations of the relevant authorities.
2. Do not operate an engine without lubrication 3. Be careful not to let discharged oil and cooling
oil or coolant. Use only the products (engine oil, water flow into the ground or the sewer. Other-
cooling water, anticorrosive agent, and etc) rec- wise, serious pollution of the drinking water
ommended by Doosan. source may occur.
3. Always keep surroundings of the engine 4. Classify the oil, filters, and filter cartridges as
clean. environmental pollution wastes and discards
them according to regulations.
4. Use fuel recommended in this Operation &
Maintenance manual. 5. Classify the antifreeze, cooling water, and an-
ticorrosive agent as hazardous wastes and dis-
5. Conduct inspections and exchanges regularly cards them according to the regulations.
according to the regular inspection table.
6. If the engine is overheated, do not stop it im- Handling of Engine Oil
mediately, but operate it at idle status for five mi-
nutes or more to lower the engine temperature Prolonged and repeated contact of skin with en-
to the proper level. gine oil may cause skin to dry out and contract,
causing dermatitis.
WARNING Engine oil includes substances toxic to the hu-
man body.
If the radiator cap is opened while the engine is still
hot, hot water will spurt out and may cause burns. Handle engine oil by observing the following
safety rules:
7. Check the engine oil level on a flat surface. 1. Do not expose skin to new engine oil for a
Do not exceed the maximum on the oil level long time.
gauge.
10-4 60068042311 EN - 07/2021 - 01

Diesel engine
2. Always wear working clothes and gloves. cause corrosion and plugging of fuel system
components.
3. If skin comes in contact with engine oil, imme- ● Use of biodiesel blend fuel may result in pre-
diately wipe it off with water, soap or hand clean-
mature failure of fuel system components,
ers. such as: plugged fuel filters and deteriorated
4. Do not clean skin with gasoline, fuel, thinner, fuel lines.
or solvent. ● Shorter maintenance intervals may be re-
quired, such as: cleaning the fuel system and
5. Apply a skin protective cream after cleaning replacing fuel filters and fuel lines.
from oil. ● Using biodiesel blended fuels containing more
6. Do not put oil-stained gloves or cloth in ones than five percent biodiesel can affect engine
pocket. life and cause deterioration of hoses, tube-
lines, injectors, injection pump, and seals.
WARNING Apply the following guidelines if biodiesel blend
fuel is used:
Discard oil according to the regulations set forth by
the relevant authorities. Disposing of discharged oil
● Ensure the fuel tank is as full as possible at
into the ground, sewers, drains, rivers, or the sea will all times to prevent moisture from collecting in
cause serious environmental pollution. Violation of the fuel rank.
regulations regarding discard of engine oil without ob- ● Ensure that the fuel tank cap is securely tight-
serving the handling regulations, will be punished. ened.
● Biodiesel blend fuel can damage painted sur-
faces, remove all spilled fuel from painted sur-
Biodiesel Blend Fuel faces immediately.
Note) Biodiesel blend fuel may also be used in ● Drain all water from the fuel filter daily before
this machine. Biodiesel blend fuel must contain operating the engine.
no more than five percent biodiesel mixed with ● Do not exceed engine oil change interval. Ex-
ultra low sulfur petroleum based diesel. tended oil change interval can cause engine
damage.
This biodiesel blend fuel is commonly marketed ● Before vehicle storage: drain the fuel tank, re-
as B5 blended diesel fuel. B5 blended diesel fuel fill with100% petroleum diesel fuel, add fuel
must meet ASTM D975 (US Standard) or EN590 stabilizer, and operate the engine for at least
(EU Standard) specifications. 30 minutes.
Biodiesel blend fuel unique qualities that should Note) Biodiesel blend fuel does not have long
be considered before using in engine term stability and should not be stored for more
● Cold weather conditions can lead to plugged than 3 month.
fuel system components and hard starting.
● Biodiesel blend fuel is excellent medium for
microbial growth and contamination that can
60068042311 EN - 07/2021 - 01 10-5

Diesel engine
Performance and specifications

Engine Specifications
Specifications
Item Remarks
DM02-MFF05
General Information
4-stroke, Inline, Water-cooled,
Engine Type
Turbocharged and Air-cooled
Combustion Chamber Type Direct Injection
Dry Liner Timing Gear System
Cylinder Liner Type
Gear Driven Type
Timing Gear System Gear Driven Type
Two Compression Rings and
Number of Piston Rings
One Oil Ring
Number of Cylinders 4
Cylinder Bore 90 mm
Cylinder Stroke 94 mm
Total Displacement 2,392 cc
Compression Ratio 16.9 : 1
Compression Pressure 25 bar at 200 rpm
Engine Dimension (L x W x H) 671 x 522 x 702 mm
Engine Weight 251 kg
Direction of Rotation Counter-clockwise View from Flywheel
Firing Order 1-3-4-2
Cooling System
Cooling Type Radiator
Capacity of Coolant 3.8 L Engine Internal Area
Centrifugal Type Driven by
Coolant Pump Type
Belt
Type Unit + Housing (Wax-Pellet)
Opening
Tempera- 82°C
Coolant Temperature
ture
Controller
Fully Open
Tempera- 97°C
ture
Coolant Temperature Sensor
Coolant Temperature Indicator
Mounted
Lubrication System
Lubricating Type Forced Lubrication System
Idle above 1.0 bar
Oil Pressure
Max. above 3.0 bar
Oil Grade API CJ-4/ACEA E6, E9
Oil Specifications SAE Vis-
SAE 10W30/40
cosity
Total 9.2 L
Oil Capacity Max. 8.6 L
Min. 4.5 L
Allowable Oil Pan Inclination Angle
35° / 35° / 35° / 35°
(Front/Rear/Left/Right)
10-6 60068042311 EN - 07/2021 - 01

Diesel engine
Gear Type Driven by Crank-

Oil Pump Type
shaft
Oil Coolant Type Water-cooled Layered Plate
Oil Strainer Type Full Flow (Cartridge)
Oil Separator Type Impact (CCV)
Hydraulic Pressure Indicator Oil Pressure Sensor
Fuel System
Fuel Injection Pump Type Bosch Common-rail Pump
Engine Control Type E.C.U (BOSCH, EDC17C87)
Delivery Pump Type Gear Type (With in CP4)
Nozzle Opening Pressure (Operating
1,800 bar
Pressure)
Injector Nozzle Type Multi Hole Type
Fuel Filter Type Full Flow (Cartridge)
Cylinder Block/Head
Valve Over Head Valve
Intake 0.0 mm HLA
Valve Clearance
Exhaust 0.0 mm HLA
Electric System
Type Electric Press-in
Start Motor
Capacity 12.0 V, 2.5 kW
Preheat System Glow Plug (12 V x 4 EA)
60068042311 EN - 07/2021 - 01 10-7

Diesel engine
Engine Performance Curve
Test evaluation method ISO8178

Engine output (rated) 36.4 kW
Torque (Max.) 205 Nm
Specific fuel consumption 224 g/kW.h
10-8 60068042311 EN - 07/2021 - 01

Diesel engine
Outside drawing of the engine

Isometric Assembly Drawings
1 Injector 15 Cylinder head cover

2 Front lifting hook 16 Cylinder head
3 Water pump pulley 17 Rear lifting hook
4 Water pump 18 Flywheel
5 V-belt 19 Flywheel housing
6 Crank shaft pulley 20 Drain coolant
7 Exhaust manifold 21 Injection pipe
8 Turbocharger 22 Alternator mounting
9 EGR cooler 23 Common rail
10 Thermostat 24 Alternator
11 Starter 25 Intake manifold
12 Timing gear case 26 Fuel injection pump
13 Oil pan 27 Oil filter
14 Breather 28 Cylinder block
60068042311 EN - 07/2021 - 01 10-9

Diesel engine
Assembly Drawings (Front/Rear)
1 Throttle valve (ACV) 10 V-belt

2 Alternator mounting 11 Timing gear case
3 Alternator 12 Breather
4 Coolant hose 13 Cylinder head cover
5 Auto tensioner 14 Cylinder head
6 Crankshaft pulley 15 Starter
7 Front lifting hook 16 Intake stake
8 Water pump pulley 17 Flywheel
9 Water pump 18 Flywheel housing
10-10 60068042311 EN - 07/2021 - 01

Diesel engine
Assembly Drawings (Left/Right)
1 Turbocharger 13 Oil cooler

2 Thermostat 14 Oil filter module
3 Oil pan 15 Fuel injection pipe
4 Drain plug 16 Intake stake
5 Exhaust manifold 17 Throttle valve (ACV)
6 EGR cooler 18 Common rail
7 Oil delivery pipe 19 Alternator
8 Oil return pipe 20 Intake manifold
9 Starter 21 Coolant hose
10 EGR valve 22 Fuel return hose
11 Oil level gauge guide tube 23 Fuel injection pump
12 Oil filter
60068042311 EN - 07/2021 - 01 10-11

Diesel engine
Assembly Drawings (Top/Bottom)
1 Thermostat 10 Common rail

2 Cylinder head cover 11 Intake stake
3 Injector 12 Oil filter
4 Turbocharger 13 Glow plug
5 Fuel return hose 14 Oil pan
6 Breather 15 Starter
7 Alternator 16 Drain plug
8 Fuel injection pipe 17 Fuel injection pump
9 Throttle valve (ACV)
10-12 60068042311 EN - 07/2021 - 01

Diesel engine
About the engine

Marking system of units
Unit Conversion Methods
The following methods show how to convert SI
units to US units and vice versa.
1. To convert an SI unit to a US unit, multiply a
SI unit with the number in the following table.
Note) (SI Unit) X (Number) = (US Unit)
Note) 1mm X 0.03937 = 0.03937 in
2. To convert a US unit to an SI unit, divide the
US unit by the number in the following table.
Note) (US Unit) ÷ (Number) = (SI Unit)
Note) 1 in ÷ 0.03937 = 25.4 mm
Item Number SI Unit US Unit

0.03937 mm in
3.28084 m ft
Length
1.093613 m yd
0.621371 km mile
0.00155 mm2 in2
0.1550 cm2 in2
Area
10.76391 m2 ft2
1.19599 m2 yd2
2.204623 kg lb
Weight
0.001 kg t (ton)
0.061024 cc in3
0.061024 ml in3
Volume 0.061024 cm3 in3
61.023744 L in3
0.264172 L gal
2.204622 kgf lbf
Forcea
0.2248089 N lbf
3.28084 m/s2 ft/s2
Acceleration
39.37008 m/s2 in/s2
7.233014 kgf·m lbf·in
86.79619 kgf·m lbf·in
Torqueb
0.7375621 N·m lbf·ft
8.850748 N·m lbf·in
Power 1.340483 kw Hp
0.01 kPa bar
7.500615 kPa mmHg
Pressure
20.88543 kPa lb/ft2
14.2233 psi kg/cm2
1.3596 kw PS
Electric Power
0.98635 ps hp
Fuel Consumption 0.00162 g/kwh lb/psh
60068042311 EN - 07/2021 - 01 10-13

Diesel engine
0.000947817 J BTU
Energy 0.7375621 J
0.0002777778 J Wh
Luminous Flux 0.09290304 lm/m2 lm/ft2
Speed 0.6213712 km/h mph
Temperature c °C °F
a. 9.806 x (kgïf) = (N)

b. 9.806 x (kgfïm) = (N·m)
c. {(9/5) x (°C)+32} = (°F)
{(°F)-32} x (5/9) = (°C)
10-14 60068042311 EN - 07/2021 - 01

Diesel engine
Tightening torque
Tightening Torque of Main Parts
Screw (Diame- Strength Tightening tor-

Major parts Remark
ter x pitch) (Grade) que (kgf.m)
Main bearing Initial 5.5 ±0.28 Not reusable
cap bolt (D18, M12 x 1.5 10.9T + angle 90° ±4° (Tier-4 Final,
D24) + angle 90° ±4° Stage-V all)
Initial 5.5 ±0.28 Not reusable
Main bearing
M12 x 1.5 12.9T + angle 90° ±4° (Tier-4 Final,
cap bolt (D34)
+ angle 90° ±4° Stage-V all)
Bed plate bolt M8 x 1.25 8.8T 2.2 ±0.22
Cylinder block
& Bed plate Plug, screw
PT 3/8 - 6.5 ±0.5
(PT)
Plug, screw
Water drain M12 x 1.5 - 3.0 ±0.3 Oil filter ass'y
plug (D18, D24)
Plug, screw
Water drain M12 x 1.5 - 5.0 ±0.5
plug (D34)
Oil spray nozzle valve M10 x 1.25 - 2 ±0.2
Not reusable
Flywheel housing, bolt M10 x 1.5 10.9T 6.2 ±0.62 (Tier-4 Final,
Stage-V all)
Not reusable
CRS V pulley, bolt M14 x 1.5 10.9T 26 ±1 (Tier-4 Final,
Stage-V all)
1st: 2.0 ±0.1 /
Connecting rod bolt (D18, D24) M8 x 1.0 10.9T
2nd: 90° ±4°
1st: 3.0 ±0.15 /
Connecting rod bolt (D34) M9 x 1.0 10.9T
2nd: 90° ±4°
Initial 6.0 ±0.3 +
MBS bolt (D34, option) M10 x 1.5 10.9T angle 90° ±4° +
angle 90° ±4°
Flywheel bolt (25 mm, option) for
M12 x 1.5 12.9T 17 ±0.85
flat type flywheel
1st: 7 ±0.35 /
Flywheel bolt (43 mm, option) M12 x 1.5 10.9T
2nd: 45° ±4°
Initial 4.0 ±0.2 +
Not reusable
angle 90° ±4° +
Head bolt (D18, D24) M11 x 1.25 9T (Tier-4 Final,
angle 90° ±4° +
Stage-V all)
angle 90° ±4°
Initial 4.5 ±0.23 Not reusable
+ angle 90° ±4° (Tier-4 Final on-
+ angle 90° ±4° ly)
Head bolt (D34) M12 x 1.25 9T
Initial 6.0 ±0.3 +
Not reusable
angle 90° ±4° +
(Stage-V only)
angle 90° ±4°
Head cover bolt (LH, RH) M6 x 1.0 8.8T 1 ±0.1
Head cover bolt (Main) M6 x 1.0 8.8T 1 ±0.1
Injector fixture bolts M8 x 1.25 12.9T 4.4 ±0.4
HP pump drive gear nut M18 x 1.5 - 8.2 ±0.5
60068042311 EN - 07/2021 - 01 10-15

Diesel engine
HP pump MTG nut M8 x 1.25 - 2.2 ±0.22

HP pipe nut - injector to rail Union nut - 3.0 ±0.3
HP pipe nut - rail to pump Union nut - 3.0 ±0.3
Thermostat MTG space bolt M8 x 1.25 8.8T 2.2 ±0.22
Thermostat plug UNF 3/4 - 16 - 1.75 ±0.25
Oil pan drain plug UNF 3/4 - 16 - 3 ±0.3
Glow plug body M8 x 1.0 - 1.05 ±0.15
Glow plug terminal M4 x 0.7 - 0.165 ±0.035
Turbocharger hollow screw M10 x 1.0 - 1.9 ±0.1
Turbocharger MTG nut M8 x 1.25 - 2.2 ±0.22
Water pump MTG nut M8 x 1.25 - 2.2 ±0.22
Rocker arm adjusting hex nut M8 x 1.0 - 1.5 ±0.15
Camshaft thrust washer bolt M8 x 1.25 8.8T 2.2 ±0.22
Idle gear shaft bolt M10 x 1.5 8.8T 4.4 ±0.44
Rocker arm Brkt bolt M8 x 1.25 8.8T 2.2 ±0.22
PTO housing bolt M10 x 1.5 12.9T 4.4 ±0.44
PTO (D24) M8 x 1.25 8.8T 2.2 ±0.22 Stage-V only
M8 x 1.25 8.8T 2nd: 2.2 ±0.22 Stage-V only
PTO (D34) Not reusable
M10 x 1.5 12.9T 1st: 4.4 ±0.44
(Tier-4 Final)
Alternator nut M8 x 1.25 - 2.2 ±0.22
Alternator bolt M8 x 1.25 8.8T 2.2 ±0.22
Starter nut M10 x 1.5 - 4.4 ±0.44
Idle pulley ass'y bolt M10 x 1.5 - 4.5 ±0.5
Extension hose Brkt bolt (Fuel) M12 x 1.75 8.8T 5.5 ±0.55
Worm drive type clamp - - 0.6 ±0.09
Band clamp (DOC & SCR) - - 1.4 ±0.1
V-clamp (Exhaust pipe) - - 1.0 ±0.1
Oil pressure sensor M14 x 1.5 - 1.0 ±0.1
EGT sensor* M14 x 1.5 - 4.0 ±0.5
Water temp. sensor M12 x 1.5 - 2.5 ±0.3
* EGT sensor Stage-V only.
Tightening Torque of General Bolts

Tightening Torque of Key General Bolts
Nominal Diameter X Pitch (mm)

Strength
M12 x
Classifi- M6 x 1 M8 x 1.25 M8 x 1 M10 x 1.5 M10 x 1.0 M12 x 1.5 M14 x 1.5
1.75
cation
Tightening Torque (kgf.m) ±10%
8.8T 1 ±0.1 2.2 ±0.22 2.4 ±0.24 4.4 ±0.44 5 ±0.5 7.5 ±0.75 8 ±0.8 13 ±1.3
1.25 3.35 10.5 11.2 18.5
10.9T 3.1 ±0.31 6.2 ±0.62 7 ±0.7
±0.13 ±0.34 ±1.05 ±1.12 ±1.85
12.5 13.4
12.9T 1.5 ±0.15 3.8 ±0.38 4.1 ±0.41 7.4 ±0.74 8.4 ±0.84 22 ±2.2
±1.25 ±1.34
10-16 60068042311 EN - 07/2021 - 01

Diesel engine
Engine disassembly
Procedure of Disassembling an Engine
NOTE
● Prepare tools and genuine parts necessary
before disassembling engine.
● Prepare a shelf for the storage of removed
parts.
● Perform repairs in a light and clean space.
● Keep hands clean while performing repairs.
● Keep parts removed from the engine in the
order of disassembly.
● Do not allow parts removed from the engine
to touch each other or be mixed with other
parts.
Disassemble the engine in the following order.
 1. Drain coolant.
1) Check if the engine and radiator are cooled.
2) Place a container in front of the coolant drain
plug.
3) Remove the radiator cap.
4) Remove the coolant drain plug of the radiator
and then drain coolant.
5) After completing coolant drain, reconnect the
coolant drain plug.
DANGER
If the radiator cap is opened while the engine is hot,
hot water will spurt out and may cause serious burns.
Open the radiator cap after making sure that the en-
gine has been fully cooled.
DANGER
Mark and separately manage the containers for stor-
ing coolant from beverage containers to avoid confu-
sion. See a doctor immediately in case of drinking
coolant.
WARNING
Discard coolant according to the regulations set forth
by the relevant authorities. Disposing of discharged
coolant into the ground, sewers, drains, rivers, or the
sea will cause serious environmental pollution. Viola-
tion of regulations when discarding engine oil without
observing the handling regulations, will be punished.
NOTE
Be careful not to get coolant on any belts or

electric apparatus when replacing the coolant.
60068042311 EN - 07/2021 - 01 10-17

Diesel engine
 Drain the engine oil. 
1) Place a container under the engine to drain

the engine oil.
2) Remove the oil cap (A).
3) Remove the drain plug (B) and drain the en-
gine oil.
WARNING
into the ground, sewers, drains, rivers, or the sea will
cause serious environmental pollution. Violation of
regulations when discarding engine oil without ob-
serving the handling regulations, will be punished.
 Detach the air cooler and cooling fan from en-

gine.
 Detach the engine from the machine.
 Disconnect the cables and harness connec-
ted to each sensor of the engine.
 Remove the V-belt. 
1) Turn the auto tensioner counterclockwise by

using a quadrangular groove at the top of the
auto tensioner pulley (Use a 10 mm x 10 mm
quadrangular tool).
2) Remove the belt wound around the auto ten-
sioner pulley by using a space generated by the
rotation of the auto tensioner.
10-18 60068042311 EN - 07/2021 - 01

Diesel engine
 Detach the alternator. 
1) Loosen bolts and remove the alternator.

2) When loosing bolt, take care not to lose nut.
 Detach the starter. 
1) Loosen 3 flange nuts.

2) Detach the starter.
 Remove the flywheel. 
1) Loosen 8 flange hex bolts.

2) Remove the flywheel.
60068042311 EN - 07/2021 - 01 10-19

Diesel engine
 Remove the flywheel housing. 
1) Loosen 8 hex bolts.

2) Remove the flywheel housing.
 Disconnect the breather hose. 
1) Remove the hose clamps.

2) Disconnect the breather hose.
 Disconnect the throttle valve (ACV) and the 

intake stake.
2) Remove the throttle valve (ACV) from the in-
take stake.
4) Remove the intake stake from the intake
manifold.
10-20 60068042311 EN - 07/2021 - 01

Diesel engine
 Disconnect oil level gauge and coolant hose. 
1) Loosen the flange hex bolt.

2) Remove the hose clamp.
3) Disconnect the coolant hose.
4) Remove the oil level gauge.
6) Disconnect the oil level gauge guide tube.
 Remove the turbocharger. 
1) Loosen 2 hollow screws and disconnect the

oil delivery pipe.
2) Loosen 4 flange hex nuts.
3) Remove the turbocharger and the gasket.
5) Disconnect the oil return pipe.
 Remove the EGR cooler. 

2) Disconnect 2 hoses.
4) Remove EGR cooler and 2 gaskets.
DANGER
Exhaust gas make engine parts extremely hot. Only
remove the parts when they have fully cooled to pre-
vent burns.
60068042311 EN - 07/2021 - 01 10-21

Diesel engine
 Remove the thermostat. 

2) Disconnect the rubber hose.
3) Loosen 2 flange hex bolt, 2 space bolt and 2
flange hex nut.
4) Remove thermostat.
 Remove the exhaust manifold. 

2) Remove the exhaust manifold and the gasket.
DANGER
vent burns.
 Remove the coolant pump pulley. 

2) Remove the coolant pump pulley.
10-22 60068042311 EN - 07/2021 - 01

Diesel engine
 Remove the coolant pump. 
1) Loosen 4 hex bolts and 2 flange hex nuts.

2) Remove the coolant pump and the gasket.
 Remove the lifting hook. 
1) Loosen flange bolt.

2) Remove the lifting hook.
 Disconnect the fuel return hose. 
1) Open the adopter (B) of injector return hose

(A).
2) Loosen the injector return hose (A).
3) Remove the edge clip (C).
4) Loosen the hose clamp (D).
5) Remove the cable tie (F), (C).
6) Disconnect the quick connector (H).
7) Disassemble the fuel return hose (A) and (E).
60068042311 EN - 07/2021 - 01 10-23

Diesel engine
 Disconnect the fuel injection pipes. 
1) Loosen the nuts connected to the injector and

the common rail.
2) Disconnect the fuel injection pipes.
3) Loosen the nuts connected to the common
rail and the fuel injection pump.
NOTE
● Do not reuse fuel injection pipes and clamp;
replace them with new ones.
● If fuel injection pipes and clamp are reused it
may allow foreign substances into the fuel
pipes or cause oil leaks from bolt clamping
and cause a critical fault in engine perform-
ance.
 Detach the common rail. 

2) Remove the common rail from the intake
manifold.
 Disconnect the EGR valve. 

2) Disconnect the hose.
4) Remove EGR valve and gasket.
10-24 60068042311 EN - 07/2021 - 01

Diesel engine
 Detach the oil cooler and the oil filter module. 
1) Detach the oil filter with the filter wrench.
NOTE
Oil in the filter may run down while detaching

the oil filter. Be careful not to contaminate the
other parts by using a cloth when detaching the
filter. After replacing the oil filter, wipe clean any
other parts which the oil has touched.
2) Remove the oil filter module and the O- rings.
4) Remove the oil cooler and the O- rings from
the oil filter module.
 Remove the intake manifold. 

2) Remove the intake manifold and the gasket.
4) Remove EGR mixer and gasket.
 Remove the right cylinder head cover. 

2) Remove the right cylinder head cover.
60068042311 EN - 07/2021 - 01 10-25

Diesel engine
 Remove the injector. 

2) Remove 4 injector fixtures.
3) Remove 4 injectors.
NOTE
Remove the cylinder head cover and remove the

injector seal ring washers.
NOTE
● Be careful not to damage the injector oil seal
of the cylinder head cover.
● Remove it by turning the injector slowly from
left to right.
● Do not reuse the injector seal ring washers.
Reuse of the injector seal ring washers may
cause critical damage to the engine due to
unstable combustion.
 Disconnect the glow plugs. 
1) Loosen 4 hex nuts.

2) Remove the electric connector.
3) Disconnect 4 glow plugs.
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Diesel engine
 Remove the cylinder head cover. 

2) Remove the cylinder head cover.
 Remove the rocker arm. 

2) Remove the rocker arm.
 Remove the push rods. 
1) Remove the push rods.
60068042311 EN - 07/2021 - 01 10-27

Diesel engine
 Detach the cylinder head. 
1) Loosen 18 cylinder head bolts.

2) Detach the cylinder head.
3) Remove the cylinder head gasket.
 Remove the valve spring. 
1) Remove the calipers.

2) Compress the valve with the valve spring
compression tool.
3) Remove the valve cotters.
4) Remove the valve spring retainers.
5) Remove the valve springs.
 Remove the valves. 
1) Remove the valves from the cylinder head.

2) Remove the valve stem seals.
3) Remove the spacer seal rings.
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Diesel engine
 Remove the crankshaft pulley. 

2) Remove the crankshaft pulley.
NOTE
Be careful not to damage the oil seal.
 Remove the timing gear case. 
 
1) Loosen the flange hex bolt and remove the

auto tensioner.
2) Loosen the fixing bolt and remove the crank
speed sensor.
4) Remove the timing gear case.
NOTE
Do not reuse the oil seal; replace them with new

ones.
60068042311 EN - 07/2021 - 01 10-29

Diesel engine
 Remove the timing wheel. 
1) Remove the timing wheel.
 Remove the fuel injection pump. 

2) Remove the fuel injection pump.
3) Loosen the flange hex nut.
4) Remove the collar.
5) Remove the O- ring from the collar.
NOTE
Do not reuse the O-ring; replace with a new

one. Reuse of the O-ring may cause critical
damage to engine performance to occur.
 Remove the oil pan. 
1) Remove the drain plug.

2) Remove the O- ring.
4) Remove the oil pan.
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Diesel engine
 Disconnect the oil suction pipe and oil deliv- 
ery pipe.
2) Remove the oil suction pipe and 1 O-ring.
4) Disconnect the oil delivery pipe and 2 O-rings.
 Remove the oil pump. 

2) Remove the oil pump and 2 O- rings.
 Remove the idle gear. 

2) Remove the idle gear shaft.
3) Remove the idle gear.
60068042311 EN - 07/2021 - 01 10-31

Diesel engine
 Remove the crank case (A). 
1) Remove the rear oil seal (E) with oil seal dis-
assembly jig.
NOTE
Do not reuse the oil seal; replace it with a new

one.
2) Loosen 16 hex bolts (B).
3) Loosen 10 main bearing cap bolts (C).
4) Remove the crank case (A).
5) Loosen 5 bottom main bearings (D) from the
crank case (A).
 Remove the crankshaft (A). 
1) Remove 2 thrust washers (B).

2) Remove the crankshaft (A).
3) Remove the top main bearings (C) from the
cylinder block.
 Remove the camshaft. 

2) Remove the camshaft.
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Diesel engine
 Remove the valve tappets (A). 
1) Remove 8 valve tappets (A) from the cylinder

block.
 Disconnect the oil spray nozzles (A). 
1) Remove 4 relief valves (B).

2) Remove 4 oil spray nozzles (A).
60068042311 EN - 07/2021 - 01 10-33

Diesel engine
Engine assembly
Procedure of Assembling Engine
NOTE
● Cleanse all disassembled and disconnected
parts. Especially, clean the oil and coolant
path with compressed air and check if there is
any resistance.
● Arrange general tools and special tools for
engine assembly.
● Prepare clean engine oil to be applied on
each sliding component.
● Prepare repair materials such as sealant and
gaskets.
● Replace used gaskets, seal rings, and ex-
pendable parts with new ones.
● Each bolt should be tightened with the speci-
fied tightening torque in the order of tighten-
ing; however, excessive tightening torque
should be avoided.
● Ensure that all engine parts are successfully
operating after reassembly.
● Check if any bolts are loose after the first as-
sembly.
● Always keep hands clean during assembly.
Assemble the engine in the following order.
 Attach the oil spray nozzles (A). 
1) Attach 4 oil spray nozzles (A) to the corre-

sponding pins.
2) Mount 4 relief valves (B) at a tightening tor-
que of 2.0 kgf·m.
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Diesel engine
 Connect the valve tappets (A). 
1) Apply engine oil on the surface where the cyl-

inder block and the valve tappets (A) are assem-
bled.
2) Connect 8 valve tappets (A).
 Attach the crankshaft (A). 
1) Mount 5 top main bearings (C) to the cylinder

block.
NOTE
● Bearings with a groove are the top main bear-
ings on the cylinder block side and bearings
without a groove are the bottom main bear-
ings on the crank case side.
● Remove foreign substances such as residues
and ThreeBond from the inside of the main
bearings and the oil seal assembly bore.
● Do not apply engine oil on the surface where
the cylinder block and the main bearings are
assembled.
● The class of the main bearing bore inside di-
ameter of the cylinder block is engraved on
the cylinder block and the class of main jour-
nal diameter of the crankshaft is engraved on
the crankshaft. For the engraving positions,
see the Engine Unique Number of chapter en-
titled “Performance and Specifications”.
● Select the proper main bearing class by
checking or measuring the class of main
bearing bore inside diameter of the cylinder
block and the class of the main journal diame-
ter of the crankshaft.
● The top main bearing class should be same
as the bottom main bearing class.
2) Sufficiently apply engine oil on the surface
where the top main bearings (C) and the crank-
shaft (A) are assembled.
3) Attach the crankshaft (A).
4) Mount 2 thrust washers (B).
60068042311 EN - 07/2021 - 01 10-35

Diesel engine
NOTE
Align the key groove of the cylinder block with

the key of thrust washer.
Note) The class of the main bearing is as fol-
lows.
Inside di- Crankshaft main journal diameter

ameter of
the cylin-
der block Class A Class B Class C
main bear-
ing bore
Class A YELLOW BLUE BLUE
Class B YELLOW YELLOW BLUE
Class C RED RED YELLOW
Inside diameter of the

cylinder block main Specified Value
bearing bore
Class A 62.000 ~ 62.007 mm
Class B 62.007 ~ 62.014 mm
Class C 62.014 ~ 62.021 mm
Note) For the method to measure the inside di-

ameter of the cylinder block main bearing bore,
refer to chapter entitled “Cylinder Block/Head”.
Crankshaft main jour-

Specified Value
nal diameter
Class A 57.955 ~ 57.960 mm
Class B 57.960 ~ 57.965 mm
Class C 57.965 ~ 57.970 mm
Note) For the method to measure the crankshaft

main journal diameter, refer to chapter entitled
“Others/Driving Units”.
Thickness of Main
Specified Value
Bearing
BLUE 1.995 ~ 2.000 mm
YELLOW 2.000 ~ 2.005 mm
RED 2.005 ~ 2.010 mm
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Diesel engine
 Attach the camshaft. 
1) Apply engine oil in the cam hole of the cylin-

der block.
2) Apply engine oil on the camshaft journal.
NOTE
Ensure that the camshaft journal and the inside

of the cylinder block bush are normal.
3) Align the thrust washer with the cylinder block
part.
4) Tighten 2 hex bolts at a tightening torque of
2.2 kgf·m.
NOTE
Temporarily mount one hex bolt manually and

then rotate the camshaft gear to tighten the oth-
er hex bolt.
5) The camshaft end play is 0.1 ~ 0.2 mm.
Item Specified Value

Camshaft end play 0.1 to 0.2 mm
 Assemble the crank case (A). 
1) Mount 5 bottom main bearings (D) to the

crank case.
NOTE
● Bearings with a groove are the top main bear-
ings on the cylinder block side and bearings
without a groove are the bottom main bear-
ings on the crank case side.
● Do not apply engine oil on the surface where
the cylinder block and the main bearings are
assembled.
● The class of main bearing bore inside diame-
ter of the cylinder block is engraved on the
cylinder block and the class of main journal
diameter of the crankshaft is engraved on the
crankshaft. For the engraving positions, see
the Engine Unique Number of chapter entitled
“Performance and Specifications”.
● Select the proper main bearing class by
checking or measuring the class of main
bearing bore inside diameter of the cylinder
block and the class of main journal diameter
of the crankshaft.
● The top main bearing class should be same
with the bottom main bearing class.
2) Sufficiently apply engine oil on the surface
where the bottom main bearings (D) and the
crankshaft are assembled.
60068042311 EN - 07/2021 - 01 10-37

Diesel engine
3) Apply sealant (TB1217H) on the crank case
assembly surface (K). Apply it on the rear part of
the engine (L) with the diameter Ø6 ±0.5 mm
and on the front part of the engine (M) with the
diameter Ø3 ±0.5 mm.
4) Assemble the crank case (A).
NOTE
● Be careful to attach the cylinder block and the
crank case in the right direction.
● Attach parts within five minutes after applying
ThreeBond onto the parts.
● Do not start the engine or load pressure with-
in 25 minutes of applying ThreeBond onto the
parts.
5) Temporarily mount 10 main bearing cap bolts
(C) in order from (1) - (10).
6) Tighten 10 main bearing cap bolts (C) at a
tightening torque of 5.5 kgf·m(±5%) + 90°(±4°) +
90°(±4°) by using the angle method.
NOTE
● Tighten the main bearing cap bolts with the
angle method.
● Tighten the main bearing cap bolts in order
from (1) - (10). The front engine direction (F)
is the water pump direction and the rear en-
gine direction (R) is the Drive Plate direction.
● Attach the crank case by tightening the main
bearing cap bolts and then the hex bolts.
7) Temporarily tighten 16 hex bolts in order.
8) Tighten 16 hex bolts (B) at a tightening torque
of 2.2 kgf·m.
NOTE
● Tighten hex bolts in order. The front engine
direction (F) is the water pump direction and
the rear engine direction (R) is the Drive Plate
direction.
● Rotate the crankshaft 2 or 3 times to check
for defects.
9) The crankshaft end play is 0.1 ~ 0.31 mm.

Crankshaft end play 0.1 ~ 0.31 mm
10)Mount the rear oil seal assembly jig to the re-

al oil seal (E) of guide (H).
11)Mount the rear oil seal assembly jig guide (H)
to the crankshaft (G).
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Diesel engine
12)Mount the rear oil seal assembly jig holder (I)
to the guide (H).
13)Turn the bolt on the center of the rear oil seal
assembly jig (I) until the rear oil seal assembly
jig holder (I) contacts with the cylinder block sur-
face (F) and the crank case surface (J) and
press in the rear oil seal (E).
NOTE
● Be careful in noting the direction of the oil
seal assembly and ensuring that the oil seal
surface faces the outside of the engine.
● Be careful of the depth of the oil seal when at-
taching it.
● Be careful not to damage the oil seal.
● Attach the oil seal without applying lubrica-
tion, coolant, fuel, ThreeBond, or silicon.
from the oil seal assembly bore.
● Do not reuse the oil seal; replace it with a new
one.
● Be careful not to damage the oil seal when at-
taching it.
 Attach the piston (A). 
1) Mount the 1st ring (D), the 2nd ring (E), and
the oil ring (F) with the piston ring plier.
NOTE
● Ensure that the 'R' mark of the piston ring
faces the top surface of the piston.
● Make the piston ring position dislocated to
120 degrees.
2) Apply engine oil on the piston pin (C).
3) Align the pin hole of the connecting rod small-
end with that of the piston (A).
60068042311 EN - 07/2021 - 01 10-39

Diesel engine
NOTE
● Be careful to mind the direction when attach-
ing the piston and the connecting rod.
● Place the product number on the top surface
of the piston, the larger side of the valve con-
tact. and the bumpy side of the piston to
make them face the front of the cylinder
block.
● Make the bumpy side of the connecting rod
face the front of the cylinder block.
● Make the direction of the bumpy side of the
piston the same as that of the bumpy side of
the connecting rod.
● The class of the inside diameter of the cylin-
der block piston bore is engraved on the cylin-
der block and the piston class is engraved on
the top surface of the piston. For the engrav-
ing positions, see the Engine Unique Number
of chapter entitled “Performance and Specifi-
cations”.
● Check or measure the class of the inside di-
ameter of the cylinder block piston bore and
the cylinder block piston to select a suitable
piston class.
● Be careful in noting the direction of the piston
and the connecting rod when attaching them.
● Make the direction of the bumpy side (H) of
the piston the same as that of the bumpy side
(I) of the connecting rod.
● If the gap between the piston ring and the
small end of the connecting rod is out of the
range of 0.025 - 0.043, replace the more worn
of the two.
Note) The classes of the cylinder block and the
piston are as follows.
Inside Diame- Piston

ter of Cylinder
Block Piston Class A Class B
Bore
Class A O -
Class B - O
Inside Diameter of Cyl-

inder Block Piston Specified Value
Bore
Class A 89.990 ~ 90.000 mm
Class B 90.000 ~ 90.010 mm
Note) For the method to measure the inside di-

ameter of the cylinder block piston bore, refer to
chapter entitled “Cylinder Block/Head”.
Piston Specified Value

Class A 89.920 ~ 89.930 mm
Class B 89.930 ~ 89.940 mm
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Diesel engine
Note) The piston class is engraved on the top
surface of the piston.
4) Attach the piston pin (C).
NOTE
● Check the attached piston and piston ring. If
the piston should be replaced, replace the
piston pin along with the piston.
● The gap between the piston pin bore and the
piston pin should be within the range from
0.008 mm to 0.019 mm.
5) Mount 2 snap rings (B) on the both ends of
the piston.
NOTE
● Do not reuse snap rings.
● Assemble snap rings with the opening of the
snap rings facing 12 o'clock.
 Mount the connecting rods. 
1) Mount the top connecting rod bearings and

the bottom connecting rod bearings.
NOTE
● Regardless of the tolerance of the connecting
rod or the crankshaft, select the top connect-
ing rod bearings and the bottom connecting
rod bearings with the yellow-marked class.
● Do not use the top connecting rod bearings
and the bottom connecting rod bearings with
the blue- or red-marked class when repairing
the engine.
● Do not apply engine oil to the assembly part
of the connecting rods and the bearings.
● You can see the oil gap by comparing the
connecting rod bearing bore with the crank-
shaft pin outside diameter.
Note) The class of the connecting rod bearing is
as follows.
Thickness of connect-
Specified Value
ing rod bearing
YELLOW 1.498 ~ 1.502 mm
2) Sufficiently apply engine oil on the inside of

the cylinder block bore and the connecting rod
bearings.
3) Mount the piston and the connecting rods to
the cylinder block with the piston insertion tool.
60068042311 EN - 07/2021 - 01 10-41

Diesel engine
NOTE
ing the piston and the connecting rod.
● Make the bumpy side of the connecting rod
face the front of the cylinder block.
● The front engine direction is the water pump
direction and the rear engine direction is the
Drive Plate direction.
● Be careful not to damage the piston and the
piston rings.
4) Attach the connecting rod caps.
NOTE
ing the connecting rods and the connecting
rod caps.
● Ensure that the number engraved on the con-
necting rods is same with that engraved on
the connecting rod caps and the assembly di-
rection is same.
5) Temporarily tighten 8 connecting rod bolts by
hand.
NOTE
Do not reuse connecting rod bolts; replace them

with new ones.
6) Tighten 8 connecting rod bolts at a tightening
torque 2.0 kgf·m + 90° by using the angle meth-
od.
NOTE
After attaching the connecting rods, rotate the

crankshaft 2 or 3 times to check whether there
is any interference.
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Diesel engine
 Attach the idle gear. 
1) Apply engine oil to the inside of the idle gear

bush in the idle gear.
2) Attach the idle gear.
CAUTION
Make sure that you are attaching the idle gear so that
its engraving faces the outside of the cylinder block.
3) Position the idle gear engraving between the

camshaft gear engravings.
NOTE
You can see two camshaft gear engravings and

one idle gear engraving.
NOTE
Make sure that the idle gear engraving is posi-

tioned between the two camshaft gear engrav-
ings.
4) Position the crankshaft gear engraving mark
between the idle gear engravings.
NOTE
You can see one crankshaft gear engraving and

two idle gear engravings.
NOTE
Make sure that the crankshaft gear engraving is

positioned between two idle gear engravings.
5) Align the flange hex holes of the cylinder
block to those of the idle gear shaft.
6) Attach the idle gear shaft.
NOTE
Make the oil hole of the idle gear shaft face the
top surface of the cylinder block.
7) Tighten 3 flange hex bolts at a tightening tor-
que of 4.4 kgf·m.
8) Backlash of the idle gear and the crankshaft
gear is 0.087 ~ 0.200 mm.

Backlash between the
idle gear and the 0.087 ~ 0.200 mm
crankshaft gear
60068042311 EN - 07/2021 - 01 10-43

Diesel engine
9) The backlash between the idle gear and the
camshaft gear is 0.087 ~ 0.211 mm.

idle gear and the cam- 0.087 ~ 0.211 mm
shaft gear
 Connect the oil suction pipe and the oil deliv- 

ery pipe.
1) Connect the oil delivery pipe and 2 O-rings.
2) Tighten 2 hex bolt at a tightening torque of 2.2
kgf·m.
3) Connect the oil suction pipe and 1 O-ring.
2.2 kgf·m.
NOTE
● Ensure that the O-rings of the inlet and the
outlet have been mounted.
● Be careful not to damage the O-rings while
mounting them.
 Attach the oil pump. 
1) Align 2 O-rings to the engine oil inlet and out-

let.
2) Align the oil pump with the pin and press it to
the cylinder block as much as possible.
2.2 kgf·m.
4) The backlash between the crankshaft gear
and the oil pump gear is 0.06 ~ 0.259 mm.

crankshaft gear and 0.06 ~ 0.259 mm
the oil pump gear
NOTE
● Make sure that the O-rings have been moun-
ted.
mounting them.
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Diesel engine
 Attach the oil pan. 
1) Apply sealant (TB1217H) to the oil pan as-

sembly surface with the diameter of Ø3 ±0.5
mm.
NOTE
● Be careful that the oil pan has been attached
in the right direction.
● Do not start the engine or load pressure for
25 minutes after applying ThreeBond onto the
parts.
2) Attach the oil pan.
que of 2.2 kgf·m.
NOTE
Tighten flange hex bolts in the order. The front

engine direction is the water pump direction and
the rear engine direction is the Drive Plate direc-
tion.
4) Mount the O- ring.
5) Connect the drain plug at a tightening torque
of 3 kgf·m.
 Attach the fuel injection pump. 
1) Mount the O- ring to the collar.

2) Mount the collar.
NOTE
● Ensure that you are attaching the injection
pump drive gear so that its engraving faces
the outside of the cylinder block.
● Ensure that the pin direction is the opposite
direction of the idle gear.
3) Tighten the flange hex nuts at a tightening tor-
que of 8.2 ±0.5 kgf·m.
4) Attach the fuel injection pump.
injection pump drive gear engravings.
NOTE
You can see two injection pump drive gear en-

gravings and one idle gear engraving.
60068042311 EN - 07/2021 - 01 10-45

Diesel engine
NOTE
● Ensure that the idle gear engraving is posi-
tioned between the two injection pump drive
gear engravings.
● Align the injection pump drive gear engrav-
ings, the idle gear engraving, and the pin of
the fuel injection pump shaft before attaching
them.
6) The backlash between the fuel injection pump
and the idle gear is 0.087 ~ 0.2 mm.

fuel injection pump and 0.087 ~ 0.2 mm
the idle gear
7) Tighten 3 flange hex nuts at a tightening tor-

que of 2.2 kgf·m.
 Attach the timing wheel. 
1) Align the timing wheel to the pin and attach it

to the crankshaft gear surface.
NOTE
Be careful not to damage the teeth of the timing

wheel.
 Attach the timing gear case. 
Note) Apply as follows and use TB121H equiva-

lent product.
Note) Apply to the surface of TGC cover with
ø2.5 ±0.5 mm thickness.
1) Make the assembly surface of the timing gear
case face the ground.
2) Mount the front oil seal to the front oil seal as-
sembly jig.
3) Align the front oil seal assembly jig where the
front oil seal is mounted to the timing gear case
and beat it with a rubber hammer.
4) when the front oil seal is inserted to the timing
gear case, pull off the front oil seal assembly jig.
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Diesel engine
NOTE
surface fasces the outside of the engine.
taching it.
tion. coolant, fuel, ThreeBond, or silicon.
one.
taching it.
5) Remove the foreign substances on the timing
gear case assembly surface and clean it with a
dry cloth.
6) Apply sealant (TB1217H) to the timing gear
case assembly surface with the diameter of
Ø2.5 ±0.5 mm.
NOTE
● Be careful that the timing gear case has been
attached in the right direction.
● Attach parts within five minutes of applying
Three- Bond onto the parts.
parts.
7) Align the timing gear case with the pin and at-
tach it.
2.2 kgf·m.
9) Mount the crank speed sensor and then tight-
en the fixing bolt.
60068042311 EN - 07/2021 - 01 10-47

Diesel engine
 Attach the crankshaft pulley. 
1) Align the crankshaft pulley to the pin and at-

tach it.
2) Tighten flange hex bolts at a tightening torque
of 26 kgf·m.
NOTE
● Fix the crankshaft to allow the flange hex
bolts to be tightened with the specified torque.
 Attach the valves. 
1) Align the valve stem seal jig to the valve stem

seal and beat it with a rubber hammer to press it
in.
NOTE
Do not give an excessive shock on the valve

stem seals; otherwise, they may be damaged.
2) Apply engine oil on the surface where the
valves and the valve stem seals are assembled.
3) Attach the valves.
NOTE
● Be careful to use the right valve without con-
fusing the intake valve with the exhaust valve.
● The intake valve has the larger valve head di-
ameter and the exhaust valve has the smaller
one.
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Diesel engine
 Attach the valve springs. 
1) Attach the valve springs.

2) Mount the valve spring retainers.
3) Compress the valve with the valve spring
compression tool.
4) Mount the valve cotters.
5) Mount the calipers.
NOTE
Check if the valve cotters have been positioned

correctly with the plastic hammer after complet-
ing attaching them.
 Attach the cylinder head. 
1. Identification mark of the cylinder head gasket

2. Cylinder head gasket class
3. Intake manifold side
4. Exhaust manifold side
1) Align the cylinder head gasket with the pin
and mount it.
NOTE
● Measure the step height of the piston top side
and select the cylinder head gasket with the
suitable class. For methods to measure the
step height of the piston top side, refer to
Measurement of the step height of the piston
top side in chapter entitled “Others/Driving
Units”.
● Be careful to mind the direction when assem-
bling the cylinder head gasket.
● Attach the cylinder head so that its identifica-
tion mark and class mark face upward.
● Align the push rod hole, the cylinder head bolt
hole, and the cylinder head gasket hole and
attach the cylinder head.
● Do not reuse the cylinder head gasket but re-
place with new one.
● Class A has one semi-circle of the identifica-
tion mark on the cylinder head gasket, Class
B has two semi-circles and Class C has three
semi-circles.
NOTE
The class of the cylinder head gasket is as fol-

lows.
60068042311 EN - 07/2021 - 01 10-49

Diesel engine
Piston protru-
Head gasket grade sionSpecification
0.50 ±0.16 mm
Thick-
Symbol Hole Over To
ness
Mark EA mm mm mm
A 1 1.02 0.34 0.45
B 2 1.12 0.45 0.55
C 3 1.22 0.55 0.66
NOTE
For method to measure the step height of the

piston top side, refer to Measurement of the
step height of the piston top side in chapter enti-
tled “Others/Driving Units”.
2) Attach the cylinder head.
3) Temporarily tighten 18 cylinder head bolts in
the order from (1) - (18).
4) Tighten 18 cylinder head bolts at a tightening
torque 4.0 kgf·m + 90°+ 90°+ 90° with the angle
method.
NOTE
● Tighten cylinder head bolts in order from (1) -
(18).
● The front engine direction is the water pump
direction and the rear engine direction is the
● Do not reuse cylinder head bolts.
● Do not apply engine oil to the cylinder head
bolts.
 Connect the push rods. 
1) Apply engine oil on both ends of the push

rods.
2) Connect the push rods in the cylinder head
holes.
3) Hit the head of the push rods with a rubber
hammer lightly once or twice to get them posi-
tioned in the tappet holes.
NOTE
After connecting the push rods, rotate them to

check the connection state.
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Diesel engine
 Attach the rocker arm. 
1) Attach the rocker arm.

que of 2.2 ±0.22 kgf·m.
 Attach the cylinder head cover. 
1) Attach the cylinder head cover.

2) Temporarily tighten 12 hex bolts.
1 ±0.1 kgf·m.
NOTE
● Be careful not to allow the seal ring of the cyl-
inder head cover to get out to the outside.
● Tighten the hex bolts of the cylinder head
cover in the order. The front engine direction
gine direction is the Drive Plate direction.
4) Mount the oil injection cap.
 Connect the glow plug. 
1) Tightening 4 glow plugs to the cylinder head

at a tightening.
2) torque of 9 ~ 12 N·m.
3) Attach the electric connector.
4) Mount 4 washers.
5) Tighten 4 hex nuts at a tightening torque of
1.3 ~ 2 N·m.
60068042311 EN - 07/2021 - 01 10-51

Diesel engine
 Attach the injectors. 
1) Align the injector seal ring washer with the

center of the injector hole and mount it.
2) Sufficiently apply engine oil on the cylinder
head cover surface where the injectors contact.
3) Attach 4 injectors.
NOTE
● Do not reuse the head cover rubber seal and
the injector oil seal but replace with new ones.
● Attach injectors by slowly turning them to pre-
vent damage to the cylinder head cover sur-
face which contacts the injectors.
Otherwise, critical damage to the engine may
occur because of unstable combustion.
4) Mount 4 injector fixtures.
NOTE
Do not tighten the hex bolts by force when it is

difficult to tighten them temporarily. Forced tight-
ening may cause damage to the cylinder head.
4.35 ±0.35 kgf·m.
 Attach the right cylinder head cover. 
1) Align the right cylinder head cover with the

assembly pin hole and attach it.
2) Temporarily tighten 10 flange hex bolts in the
order.
que of 1 ±0.1 kgf·m.
10-52 60068042311 EN - 07/2021 - 01

Diesel engine
 Attach the intake manifold. 
1) Mount the intake manifold and the gasket.
NOTE
● Be careful to note the direction when mount-
ing the gasket.
● Be careful not to damage the gasket while
mounting it.
2) Tighten 11 flange hex bolts and 2 flange hex
bolts at a tightening torque of 2.2 kgf·m.
3) Attach EGR mixer and gasket to the intake
manifold.
que 2.2 kgf·m.
 Attach the oil cooler and the oil filter module. 
1) Mount the oil cooler and 3 O-rings to the oil

filter module.
2) Tighten 3 flange hex bolts.
3) Mount the oil filter module and 3 O- rings to
the cylinder block.
NOTE
ted.
mounting them.
que of 2.2 kgf·m.
5) Wipe the surface on which the oil filter is
mounted clean.
6) Thinly spread engine oil over the rubber pack-
ing of the new oil filter.
7) Temporarily mount the oil filter by turning it by
hand.
8) Mount the oil filter with the filter wrench at a
tightening torque of 16 ~ 20 N·m.
60068042311 EN - 07/2021 - 01 10-53

Diesel engine
 Attach the EGR valve. 
1) Attach the EGR valve and gasket to the in-

take manifold.
NOTE
The EGR valve has to be handled with care, be-

cause it is sensitive to external impact.
que 2.2 kgf·m.
3) Assemble hose and clamps.
 Attach the common rail. 
1) Attach the common rail to the intake manifold.
NOTE
● Be careful to note the direction when attach-
ing the common rail.
● Be careful not to damage the common rail
while attaching it.
2) Temporarily tighten 2 hex bolts by hand.
2.2 kgf·m.
 Connect the fuel injection pipes. 
1) Loosen 2 hex bolts of the common rail.

2) Temporarily connect the fuel injection pipes
by hand.
NOTE
● Do not bend the fuel injection pipes by force.
● Be careful to note the direction when connect-
ing the fuel injection pipes.
● Assemble the nut on one side of the fuel in-
jection pipe first, and then the nut on the other
side to connect the round part of the pipe to
the correspondent part correctly.
replace them with new ones. Reusing fuel in-
jection pipes and clamp may allow foreign
substances into the fuel pipes or oil leaks
from the bolt clamping to occur, causing a
critical fault in engine performance.
10-54 60068042311 EN - 07/2021 - 01

Diesel engine
3) Tighten 2 hex bolts of the common rail at a
tightening torque of 2.2 kgf·m.
4) Tighten the nuts of the fuel injection pipe,
which are connected to the common rail and the
injector, at a tightening torque of 3.0 kgf·m.
fuel injection pump, at a tightening torque of 3.0
kgf·m.
 Connect the fuel return hose. 
1) Press the fuel return hose into the end of the

nipple and connect it.
NOTE
ing the fuel return hose.
● The injector should be fully connected with
the hose.
2) Mount 4 hose clips.
3) Mount the hose clips.
NOTE
Fix the handle of hose clip to face the front of

the engine.
4) Tighten the flange hex bolts.
5) Mount the fixing clips.
 Mount the rear and front lifting hook. 
1) Mount the rear lifting hook.

que of 4.4 kgf·m.
3) Mount the front lifting hook.
que of 2.2 kgf·m.
60068042311 EN - 07/2021 - 01 10-55

Diesel engine
 Attach the water pump. 
1) Align the gasket with the stud bolts and mount

it.
2) Align the coolant pump with the stud bolts and
attach it.
4) Tighten 4 hex bolts and 2 flange hex nuts at a
NOTE
● Do not allow the gasket to protrude from or be
to one side of the coolant pump.
mounting it.
 Attach the water pump pulley. 
1) Attach the water pump pulley.

2.2 kgf·m.
 Attach the exhaust manifold. 
1) Mount the gasket so that the TOP mark faces

the top surface and the front of the engine.
2) Attach the exhaust manifold.
que 3.1 kgf·m.
10-56 60068042311 EN - 07/2021 - 01

Diesel engine
 Attach the heat screen. 
1) Temporarily tighten 2 hex bolts to the exhaust

manifold side.
2) Mount the heat screen.
3) Tighten 2 hex bolts.
que 1.25 kgf·m.
NOTE
● Be careful to note the direction in which the
gasket is mounted. Mount the gasket so that
the TOP mark faces the front of the engine.
mounting it.
 Mount the thermostat. 
1) Mount the thermostat to the cylinder head.

2) Tighten 2 flange hex bolt, 2 space bolt and 2
flange hex nut as a tightening.
que of 2.2 kgf·m.
4) Connect the rubber hose.
5) Mount the hose clamps.
NOTE
● After mounting the hose clamps, make the
protrusion face the cylinder head side to pre-
vent interference between the protrusion and
the coolant pump pulley.
● Do not use the hose clamps more than twice;
 Attach the EGR cooler. 
NOTE
ing the EGR cooler.
mounting it.
1) Mount the EGR cooler and gaskets to the ex-
haust manifold and cylinder head.
que of 3.1 kgf·m. (exhaust manifold side)
que of 2.2 kgf·m. (cylinder head side)
4) Assemble 2 hoses and clamps.
60068042311 EN - 07/2021 - 01 10-57

Diesel engine
NOTE
Do not reuse the clamps if it has permanent de-

formation by irregular shape.
 Assemble the turbocharger. 
1) Connect the oil return pipe and gasket to the

turbocharger.
que of 1.0 kgf·m.
3) Mount the turbocharger and the gasket to the
exhaust manifold.
NOTE
ing the gasket.
mounting it.
que of 2.2 kgf·m.
5) Assemble the gasket between oil return pipe
and cylinder block. Tighten 2 flange hex nuts at
a tightening torque of 1.0 kgf·m.
NOTE
Do not reuse the clamp if it has permanent de-

6) Temporary tighten 2 hollow screws to the oil
delivery pipe manually.
7) Tighten 2 hollow screws at a tightening torque
of 1.9 kgf·m.
NOTE
● Do not reuse the oil supply pipe.
● Tighten the hollow screw at the cylinder block
side first, and then tighten the other at the tur-
bocharger side.
10-58 60068042311 EN - 07/2021 - 01

Diesel engine
 Mount the oil level gauge and the coolant 
hose.
1) Replace the O- ring of the oil level gauge
guide tube with a new part.
2) Insert the oil level gauge guide tube in the cyl-
inder block and connect it.
of 1.0 kgf·m.
4) Mount the oil level gauge.
NOTE
Make the handle of the oil level gauge face the

reverse direction from the center of the engine.
5) Connect the coolant hose.
NOTE
Do not use hose clamps more than twice; re-

place them with new ones.
at a tightening torque of 2.2 kgf·m.
 Connect the throttle valve (ACV) and the in- 
take stake.
1) Mount the intake stake to the intake manifold.
NOTE
ing the gasket.
mounting it.
2.2 kgf·m.
3) Assemble the throttle valve to the intake
stake.
NOTE
ing the gasket.
mounting it.
2.2 kgf·m.
60068042311 EN - 07/2021 - 01 10-59

Diesel engine
 Connect the breather hose. 
1) Connect the breather hose.

NOTE

 Attach the flywheel housing. 
1) Align the flywheel housing to the pin and at-

tach it.
6.2 kgf·m.
 Mount the flywheel. 
1) Mount the flywheel.

2) Tighten 8 Flange hex bolts at tightening bolt
torque.
Flywheel bolt (43 mm, 1st: 7 ±0.35 / 2nd: 45°

option) ±4°
Flywheel bolt (25 mm,
option) for flat type fly- 17 ±0.85
wheel
NOTE
Be careful that no foreign material (oil, etc.) is

present in the bolt and tap.
10-60 60068042311 EN - 07/2021 - 01

Diesel engine
 Attach the starter. 
1) Align the starter with the pin and attach it.

2) Tighten 3 flange nuts at a tightening torque of
4.4 kgf·m.
 Attach the alternator. 
1) Using bolt B and nut, attach the alternator

temporarily.
2) By tightening bolt, set the position of the alter-
nator properly.
3) Tighten bolts to a torque of 4.4 kgf·m.
 Attach the V-belt. 
1) Wind a new belt around all pulleys except for

the auto tensioner.
quadrangular tool).
3) Wind the belt around the auto tensioner pulley
by using a space generated by the rotation of
the auto tensioner, and then naturally release
the tensioner that has been pulled counterclock-
wise.
NOTE
For checking and measuring the belt tension, re-

fer to Belt Tension in chapter entitled “Others/
Driving Units”.
 Connect the cables and harness connected to
each sensor of the engine.
60068042311 EN - 07/2021 - 01 10-61

Diesel engine
 Attach the engine to the machine.
 Assemble the air cooler and the cooling fan
on the engine.
 Inject the engine oil.
1) Open the oil injection cap on the cylinder
head cover top and inject engine oil.
NOTE
Use genuine engine oil recommended by Doo-

san.
 Inject coolant.
1) Open the radiator cap and add coolant.
NOTE
Use coolant recommended by Doosan.
Cooling system
General information 
This engine is water-cooled. It uses coolant to

cool the engine by absorbing heat from the com-
bustion chamber and the engine oil and then re-
leases the heat, allowing for normal engine op-
eration.
In this cooling unit system, coolant provided by
the water pump flows into the oil cooler through
the coolant pipe to absorb oil heat and passes
through the coolant jacket of the cylinder block
and the cooling path of the cylinder head to ab-
sorb the combustion heat.
Coolant which absorbed the oil and combustion
heat flows into the thermostat through the cool-
ant pipe. If the coolant temperature is lower than
the valve-opening temperature of the thermo-
stat, the coolant flows into the water pump. If 1 Radiator
2 water pump
higher, it flows into the radiator. The radiator re- 3 Cylinder Block
leases the heat absorbed from the coolant and 4 Cylinder head
sends the coolant to the water pump again. 5 Oil cooler
6 EGR Valve
7 EGR cooler
8 thermostat
9 Bypass
Failure Diagnosis
Phenomenon Causes Troubleshooting
Overheated engine Not enough coolant Replenish the coolant
10-62 60068042311 EN - 07/2021 - 01

Diesel engine
Defective radiator cap Replace it

Contaminated radiator Clean the exterior of the radiator
Defective V-belt offset Adjust or replace it
Contaminated or damaged V-
Replace it
belt
Damaged impeller Replace the water pump
Defective impeller fix Replace the water pump
Bad water pump operation Replace it
Bad thermostat operation Replace it
Bad coolant flow Clean the coolant path
Check it with the failure diagno-
Improper injection time
sis unit
Damaged cylinder head gasket Replace it
Bad thermostat operation Replace it
Overcooled engine
Too low ambient temperature Heat the block
Damaged radiator Repair or replace it
Loosened or damaged radiator
Repair or replace the connection
connection
Defective radiator cap Replace it
Badly mounted water pump Repair or replace it
Bad or damaged water pump
Leaking coolant Replace the gasket
gasket
Badly mounted thermostat Repair or replace it
Bad or damaged thermostat gas-
Replace the gasket
ket
Damaged cylinder head gasket Replace the gasket
Damaged cylinder head or block Replace it
Bad water pump bearing Replace the bearing
Bad or damaged cooling fan Repair or replace it
Noise
Bad rotation of the cooling fan Replace it
Defective V-belt offset Adjust or replace it
Water pump
General Information
The water pump prevents the engine from being
overheated by combustion heat during engine
operation and delivers coolant from the radiator
to each part of the engine.
60068042311 EN - 07/2021 - 01 10-63

Diesel engine
Water Pump Disassembly
 Drain coolant. 
1) Check if the engine and radiator are cooled.

2) Place a container in front of the coolant drain
plug.
3) Remove the radiator cap.
4) Remove the coolant drain plug of the radiator
and then drain coolant.
5) After completing coolant drain, connect the
coolant drain plug again.
DANGER
Do not open the radiator cap while the engine is over-

heated. If the radiator cap is opened while the engine
is heated, hot water will spurt out and may cause seri-
ous burns. Open the radiator cap after making sure
that the engine has been fully cooled.
Mark and separately manage the containers for stor-
ing coolant from beverage containers for avoiding
confusion. See a doctor immediately in case of drink-
ing coolant.
WARNING
Discard exchanged coolant according to the regula-
tions set forth by the relevant authorities. Disposing of
exchanged coolant into the ground, sewers, drains,
rivers, or the sea will cause serious environmental
pollution. Violation of regulations regarding discard of
engine oil without observing the handling regulations
will be punished.
NOTE
Be careful not to allow coolant to touch any belts

or electric apparatus when replacing the cool-
ant.
10-64 60068042311 EN - 07/2021 - 01

Diesel engine
 Remove the micro V belt 

quadrangular tool).
 Remove the coolant pump pulley. 

2) Remove the coolant pump pulley.
 Remove the coolant pump. 
1) Loosen 4 hex bolts and 2 flange hex nuts.

2) Remove the coolant pump and the gasket.
60068042311 EN - 07/2021 - 01 10-65

Diesel engine
Water Pump Assembly
 Attach the water pump. 
1) Align the gasket with the stud bolts and mount

it.
2) Align the coolant pump with the stud bolts and
attach it.
4) Tighten 4 hex bolts and 2 flange hex nuts at a
NOTE
● Do not allow the gasket to protrude from or be
to one side of the coolant pump.
mounting it.
 Attach the water pump pulley. 
1) Attach the water pump pulley.

2.2 kgf·m.
1) Using bolt and nut, attach the alternator tem-

porarily.
nator properly.
3) Tighten bolts to a torque of 4.4 kgfm.
10-66 60068042311 EN - 07/2021 - 01

Diesel engine
1) Turn the auto-tensioner counterclockwise

when viewed toward the auto tensioner, and re-
move the belt.
 Add coolant.
1) Open the radiator cap and add coolant.
NOTE
Use coolant recommended by Doosan.
Thermostat
General Information 
The thermostat maintains water temperature in

the engine consistently and prevents heat loss
to improve heat efficiency of the engine.
When the coolant temperature is below the nor-
mal temperature, the thermostat is closed and
the coolant is bypassed and directly flows into
the water pump. When the coolant temperature
reaches the normal temperature or is higher
than the temperature, the thermostat is fully
open and the bypass circuit is closed. So the
coolant flows into the radiator.
NOTE
● The wax pellet type thermostat shows slower
response to the change of cooling water than 1 Radiator
the bellows type thermostat. This happens 2 Bypass valve
because the heat capacity of the wax pellet 3 Water pump
type thermostat is larger than that of the bel- 4 Coolant inlet
lows type thermostat. Therefore, to prevent a
rapid increase in the engine coolant's temper-
ature, you must first operate the engine at idle
until the engine is fully warmed up. When the
weather is very cold, do not operate the en-
gine in an overloaded condition or at a high
speed after starting the engine.
● When draining water from the engine cooler
or injecting water to the engine cooler, work
slowly to ensure that all air inside the cooler is
expelled.
● When a defect is found in the thermostat, re-
place it with a new one.
60068042311 EN - 07/2021 - 01 10-67

Diesel engine
Thermostat Disassembly
NOTE
Detaching the thermostat itself may degrade

cooling performance. Do not detach the thermo-
stat itself.
 Drain coolant until the coolant level is below
the thermostat height.

3) Loosen 2 flange hex bolts, 2 space bolts and
2 flange hex nuts.
Thermostat Assembly

2) Tighten 2 flange hex bolts, 2 space bolts and
2 flange hex nuts as a tightening.
que of 2.2 kgf·m.
NOTE
 Replenish the coolant.
Check of Thermostat
 Check whether the wax pellet and the spring
are damaged or not.
10-68 60068042311 EN - 07/2021 - 01

Diesel engine
 Put the thermostat into water and heat the
water slowly to inspect thermostat operation.
 If the thermostat starts open approximately 
0.3 mm at a water temperature of 82°C and is
fully open at more than 8.0 mm at a water
temperature of 97 °C, the thermostat is nor-
mal.
A. Thermometer
B. Measuring point
 Check if there are any foreign substances in
the thermostat.
NOTE
Clean the inside of the thermostat with an air

gun.
 Check if there are any foreign substances or
damaged parts inside and outside of the
hose.

Thermostat Open 0.3 mm (at 82°C) 8.0
Temperature mm or larger (at 97°C)
60068042311 EN - 07/2021 - 01 10-69

Diesel engine
Lubrication system
General information
General Information
1 Oil pump 8 Idle gear

2 Relief Valve 9 Piston
3 Bypass Valve 10 Crankshaft main bearing
4 Oil cooler 11 Connecting rod bearing
5 Oil filter 12 Camshaft bearing
6 Bypass Valve 13 Rocker arm
7 Piston cooling jet 14 Turbocharger
This engine is a forced lubrication type of en-

gine. Oil pressure is generated and delivered by
rotating the gear of the oil pump which is directly
engaged with the crankshaft gear on the front of
the cylinder block.
10-70 60068042311 EN - 07/2021 - 01

Diesel engine
The oil pump delivers oil sucked from the oil pan
with the suction pipe to the main path of the cyl-
inder block through the oil cooler and oil filter.
From the cylinder block, oil is delivered to the
crankshaft bearings, camshaft bearings, and
rocker arm for lubrication. In addition, the turbo-
charger is connected to the engine lubrication
circuit. Around the cylinder block and the timing
gear, lubricating oil is dispersed. Each cylinder
has an oil injection nozzle for cooling the bottom
of the piston. Engine oil is filtered through the oil
filter and purified.
Failure Diagnosis
Bad oil Replace oil with specified oil
Oil leakage from the oil seal ring
Replace it
and packing part
Worn or damaged piston and
Replace it
Too much oil consumption piston ring
Worn cylinder liner Replace it
Burnt piston ring Replace it
Worn valve guide oil seal, valve
Replace it
guide, or valve stem
Burnt oil pump relief valve Replace it
Clogged oil pump strainer Cleanse the strainer
Worn oil pump gear Replace it
Low oil pressure Cracked oil delivery pipe of the
Replace it
oil pump
Defect oil pump Repair or replace it
Oil pressure gauge fault Repair or replace it
Worn bearings Replace it
Replace the oil filter with a new
Clogged oil filter
one
Contaminated oil Replace piston ring with a new
Gas leakage
one
Oil pump
General Information
Engine oil is sucked from the oil pan by the gear
type oil pump and then all of the oil is forcibly
delivered to the oil cooler and filter for filtering.
The filtered oil passes through the main oil path
of the cylinder block and lubricates bearing parts
and the turbocharger of the engine in order to
maintain normal engine performance.
60068042311 EN - 07/2021 - 01 10-71

Diesel engine
Oil Pump Disassembly

the engine oil.
gine oil.
WARNING

quadrangular tool).

NOTE
10-72 60068042311 EN - 07/2021 - 01

Diesel engine

speed sensor.
NOTE

ones.
 Remove the oil pump. 

2) Remove the oil pump and 2 O- rings.
60068042311 EN - 07/2021 - 01 10-73

Diesel engine
Oil Pump Assembly
 Attach the oil pump. 
1) Align 2 O-rings to the engine oil inlet and out-

let.
2) Align the oil pump with the pin and press it to
the cylinder block as much as possible.
2.2 kgf·m.
4) The backlash between the crankshaft gear
and the oil pump gear is 0.06 ~ 0.259 mm.

the oil pump gear
NOTE
ted.
mounting them.

NOTE

wheel.
10-74 60068042311 EN - 07/2021 - 01

Diesel engine
Note Apply as follows and use TB121H equiva-

lent product.
Note Apply to the surface of TGC cover with
sembly jig.
NOTE
taching it.
one.
taching it.
dry cloth.
Ø2.5 ±0.5 mm.
NOTE
parts.
tach it.
2.2 kgf·m.
60068042311 EN - 07/2021 - 01 10-75

Diesel engine
en the fixing bolt.

tach it.
of 26 kgf·m.
NOTE
1) Fix the V-belt to the alternator pulley, the

coolant pump, and the crankshaft pulley and
mount it.
2) Check that the V-belt is precisely engaged
with the groove of each pulley with naked eye.
NOTE

Driving Units”.
NOTE

san.
Check of Oil Pump

1. With the gap gauge, check if the oil pump
gear backlash is within the range of 0.06 ~ 0.259
mm.
2. Make sure that the oil pump gear spins
smoothly when spinning it with the torque of 3.0
kgf·cm.

Oil pump gear back-
0.06 ~ 0.259 mm
lash
10-76 60068042311 EN - 07/2021 - 01

Diesel engine
Disassembly of Oil Suction Pipe and Oil De-
livery Pipe

the engine oil.
gine oil.
WARNING

 Disconnect the oil suction pipe and oil deliv- 

ery pipe.
2) Remove the oil suction pipe and 1 O-ring.
4) Disconnect the oil delivery pipe and 2 O-rings.
60068042311 EN - 07/2021 - 01 10-77

Diesel engine
Assembly of Oil Suction Pipe and Oil Deliv-
ery Pipe
 Connect the oil suction pipe and the oil deliv- 
ery pipe.
1) Connect the oil delivery pipe and 2 O-rings.
2) Tighten 2 hex bolt at a tightening torque of 2.2
kgf·m.
3) Connect the oil suction pipe and 1 O-ring.
2.2 kgf·m.
NOTE
● Ensure that the O-rings of the inlet and the
outlet have been mounted.
mounting them.

mm.
NOTE
parts.
que of 2.2 kgf·m.
NOTE

tion.
of 3 kgf·m.
10-78 60068042311 EN - 07/2021 - 01

Diesel engine
NOTE

san.
Oil filter assembly

General Information
The oil cooler cools oil with coolant and the oil
filter removes the foreign substances from the
oil.
Disassembly of Oil Filter Assembly


the engine oil.
gine oil.
WARNING

60068042311 EN - 07/2021 - 01 10-79

Diesel engine
NOTE

Assembly of Oil Filter Assembly


filter module.
the cylinder block.
NOTE
ted.
mounting them.
que of 2.2 kgf·m.
mounted clean.
hand.
10-80 60068042311 EN - 07/2021 - 01

Diesel engine
hose.
of 1.0 kgf·m.
NOTE

NOTE

Check of Oil Cooler

1. Check if the coolant inlet of the oil cooler is
damaged and if coolant has leaked.
2. Check if the oil inlet and outlet of the oil cooler
are damaged and if oil has leaked.
3. Check if the exterior of the oil cooler is dam-
aged and leakage has occurs.
60068042311 EN - 07/2021 - 01 10-81

Diesel engine
Oil pan
Disassembly of Oil Pan

the engine oil.
gine oil.
WARNING

10-82 60068042311 EN - 07/2021 - 01

Diesel engine
Assembly of Oil Pan

mm.
NOTE
parts.
que of 2.2 kgf·m.
NOTE

tion.
of 3 kgf·m.
NOTE

san.
60068042311 EN - 07/2021 - 01 10-83

Diesel engine
Disassembly of Engine Oil Level Gauge
and Guide Tube

Assembly of Engine Oil Level Gauge and

Guide Tube
hose.
of 1.0 kgf·m.
NOTE

NOTE

10-84 60068042311 EN - 07/2021 - 01

Diesel engine
Fuel system
General Information
1 Tank with pre-filter 4 Common rail

2 Electronic control unit 5 Fuel injection pump
3 Injector
A diesel engine creates combustion through the

compression heat generated by compressing air
inhaled into the cylinder and the fuel injected by
the fuel injection nozzle.
The high-pressure fuel generated by the high-
pressure pump is stored in the common rail. The
timing and amount of fuel injection is calculated
by the Electronic Control Unit (ECU). The ECU
injects fuel by operating the solenoid valve for
the injector installed in each cylinder.
60068042311 EN - 07/2021 - 01 10-85

Diesel engine
Doosan's common rail fuel injection system sep-
arates the high-pressure apparatus from the fuel
injection apparatus. Depending on the condi-
tions of engine operation, the ECU decides fuel
volume, fuel injection timing, and pressure for
optimum performance and injects fuel in the cyl-
inder.
The common rail fuel injection system consists
of the low-pressure level for low-pressure fuel
transfer, the high-pressure level for high-pres-
sure fuel transfer, and the ECU.
The fuel tank should be anti-corrosive. No fuel
should be leaked from the fuel tank under the
doubled operating pressure of the fuel low-pres-
sure pump. The pressure in the tank should not
exceed 0.3 bars.
Fuel return hose

General Information
This hose is to transfer the fuel returned from
the injector to the high-pressure pipe back.
Disconnection of Fuel Return Hose


(A).
10-86 60068042311 EN - 07/2021 - 01

Diesel engine
Connection of Fuel Return Hose

NOTE
the hose.
NOTE

the engine.
Check of Fuel Return Hose

1. Check if there is any foreign substance or
damaged part in the inside and the outside of
the fuel line.
2. Check if oil is leaked from the joints.
3. Check if the adaptor is damaged and oil is
leaked.
Injector
General Information
The injector uses the nozzle to inject fuel to the
combustion chamber directly. To control the in-
jection, the solenoid valve is used. Fuel is deliv-
ered as much as required from the open injector
nozzle and the remaining fuel is returned to the
fuel tank through the fuel return line. In addition,
the fuel which has been used to lubricate the
high-pressure pump and returned from the fuel
pressure adjustment valve is returned to the fuel
tank through the return line.
The solenoid valve controls the fuel injection tim-
ing and amount. The injector works instead of
the nozzle and the nozzle holder mounted on
the existing engine. Fuel is delivered to the in-
jector through the high-pressure connector
mounted on the cylinder head and then deliv-
ered to the valve control chamber through the
delivery hole.
60068042311 EN - 07/2021 - 01 10-87

Diesel engine
The valve control chamber is opened by the so-
lenoid valve. It is connected to the fuel return
line via the discharge hole. The hydraulic force
which has been increased by the valve control
plunger with closed discharge hole exceeds the
pressure value of the nozzle needle. As a result,
fuel delivery to the combustion chamber is
blocked by the force given to the contact surface
of the nozzle needle.
When the solenoid valve of the injector is pulled,
the discharge hole is opened. This lowers the
pressure in the control chamber and the hydraul-
ic power given to the plunger. When hydraulic
force is lower than the force given to the nozzle
needle pressure, the nozzle needle is opened.
Finally, fuel is injected to the combustion cham-
ber through the injection nozzle hole.
The reason that the nozzle needle is controlled
by hydraulic force is that the power required to
open the needle quickly cannot be directly gen-
erated from the solenoid valve. Fuel control
amount required to open the nozzle needle is
added to the fuel amount injected. The used fuel
is discharged to the fuel return line through the
hole of the valve control chamber.
Fuel loss occurs on the nozzle needle, the valve
plunger guide as well as the valve control cham-
ber. The control leakage fuel and the fuel gath-
ered from the line, which connects the over flow
valve, the high-pressure pump, and the pressure
control valve, is returned to the fuel tank through
the fuel return line.
How to Operate an Injector

Injector operation is classified into four operation
stages to operate the engine and create pres-
sure in the high-pressure pump.
1. The injector is closed (high fuel pressure
state)
2. The injector is open (starting fuel injection).
3. The injector is fully open (injecting fuel).
4. The injector is closed (ending fuel injection).
These operation stages are decided by balanc-
ing the force given to the injector components. If
there is no pressure on the common rail or the
engine is stopped, the injector nozzle does not
work.
1. The injector is closed (pause state)
Under the pause state that no power is provided
to the solenoid valve of the injector, the injector
does not operate. The surface where the dis-
charge hole exists is tightly closed with the valve
10-88 60068042311 EN - 07/2021 - 01

Diesel engine
ball by the force from a valve spring or magnet.
High pressure in the common rail is kept by the
fuel control valve and the same pressure is gen-
erated in the nozzle chamber of the injector. The
common rail fuel pressure, which is given to the
end face of the valve control chamber of the in-
jector, and the injector nozzle spring force are
larger than the force to open the nozzle. There-
fore, the injector is closed.
2. The injector is open. (starting fuel injection)
When power is supplied while the injector sole-
noid valve is closed, the fuel discharge hole is
open by the pulling force of the solenoid valve.
Almost simultaneous with that, the high current
given to the solenoid valve is reduced to the low
current. This is because the air gap of the elec-
tromagnet circuit gets smaller. Fuel in the valve
control chamber flows to the discharge valve
hole on the upper side and then goes into the
fuel tank via the fuel return line. The discharge
hole completely breaks the pressure balance
and lowers the pressure in the valve control
chamber. As a result, the pressure in the valve
control chamber is lower than the nozzle cham-
ber pressure which has been equal to the com-
mon rail pressure. The lowered pressure of the
valve control chamber lowers the force from the
control plunger. So the nozzle needle is open
and fuel injection starts.
3. The injector is fully open. (injecting fuel)
The valve control plunger is stopped at the up-
per position because fuel is full as fuel flows
from the fuel delivery hole. At this time, the injec-
tor nozzle is fully open and fuel is injected to the
combustion chamber at the pressure equal to
that of the common rail.
4. The injector is closed. (ending fuel injection)
As soon as the supply to the solenoid vale of the
injector is blocked, the valve spring applies force
to the armature downward and the valve ball
closes the discharge hole. The armature con-
sists of two components. The armature plate is
guided by the driving shoulder and pressed
downward. However, in this case, an overspring
is used. It is a return spring that prevents the
force from being applied to the armature and the
valve ball. As the discharge hole is closed, fuel
is delivered from the delivery hole and generates
pressure in the control chamber. This fuel pres-
sure is equal to the pressure of the common rail
and puts pressure on the valve control plunger
through the end face of the valve control plung-
er. As a result, the force of the spring is added to
the pressure exceeding the pressure of the noz-
zle chamber. Therefore, the nozzle needle is
60068042311 EN - 07/2021 - 01 10-89

Diesel engine
closed. The speed of closing the nozzle needle
is decided by the flow that passes through the
delivery hole. As soon as the nozzle needle is
positioned to the stop position, fuel injection is
blocked.
Injector Disassembly


(A).
10-90 60068042311 EN - 07/2021 - 01

Diesel engine

the common rail.
CAUTION
Do not reuse fuel injection pipes
and clamp; replace them with new
ones.If fuel injection pipes and
clamp are reused it may allow for-
eign substances into the fuel pipes
or cause oil leaks from bolt clamp-
ing and cause a critical fault in
engine performance.


NOTE

60068042311 EN - 07/2021 - 01 10-91

Diesel engine
NOTE
left to right.
Injector Assembly

NOTE
NOTE

4.35 ±0.35 kgf·m.
10-92 60068042311 EN - 07/2021 - 01

Diesel engine

order.

by hand.
NOTE
kgf·m.
60068042311 EN - 07/2021 - 01 10-93

Diesel engine

NOTE
the hose.
NOTE

the engine.

NOTE

Injector Check
 Check if there are any foreign substances and
if the end part of the injector is transformed.
10-94 60068042311 EN - 07/2021 - 01

Diesel engine
 Check the injector protrusion (C). 
1) Detach the cylinder head (A).
NOTE
Detach the cylinder head by referring to engine

disassembly order.
2) Insert the seal ring in the cylinder head (A)
and attach the injector (B).
3) Check the injector protrusion (C) based on
the cylinder head (A) surface with a dial gauge.
NOTE
Be careful not to allow foreign substances to

flow into the injector and the high-pressure con-
nector when detaching and checking the injec-
tor.

Injector protrusion 1.5 ±0.65 mm
60068042311 EN - 07/2021 - 01 10-95

Diesel engine
Common rail
General Information
1 Tank with pre-filter 4 Common rail

2 Electronic control unit 5 Fuel injection pump
3 Injector
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Diesel engine
Doosan's common rail fuel injection system sep- 
arates the high-pressure apparatus from the fuel
injection apparatus. The ECU decides the fuel
amount and the fuel injection timing and pres-
sure for the optimum performance and injects
fuel in the cylinder.
The high-pressure fuel generated from the fuel
high-pressure pump is stored in the common
rail. When a driver operates the vehicle, fuel in-
jection timing and optimum fuel amount are deci-
ded based on the data set in the Electronic Con-
trol Unit (ECU) and the solenoid valve of the in-
jector installed in each engine cylinder is operat-
ed to inject fuel into the cylinder.
Main components of the common rail fuel injec-
tion system are as follows.
1. Electronic Control Unit (ECU)
1) The Electronic Control Unit (ECU) receives
the input signals generated by the above input
sensors based on the driver's accelerator opera-
tion and works immediately according to the
driving performance of the engine and the vehi-
cle. In addition, based on the above information,
the ECU generates open/close circuit - circula-
tion circuit operations of the vehicle and engine.
2) The engine speed is measured by the crank-
shaft RPM sensor and the ignition order is deter-
mined by the camshaft RPM sensor. Through
electrical signals generated by the potentiometer
of the accelerator pedal sensor, shows how
strong the driver has pressed the pedal. In addi-
tion, the ECU includes the turbocharger and the
intake pressure sensor. The intake pressure
sensor measures the intake pressure.
3) When it is very cold or the engine is cooled,
the ECU receives data from the coolant temper-
ature sensor and the air temperature sensor to
operate with the best conditions for engine oper-
ation.
2. Crankshaft RPM sensor
1) Position of the piston in the combustion
chamber is very important. Pistons of all engines
are connected to the crankshaft via the connect-
ing rods. The crankshaft RPM sensor installed in
the Drive Plate housing provides information on
the position of all pistons. The rev-speed is de-
fined as Revolutions per Minute (RPM) of the
crankshaft. The key input parameters are calcu-
lated by the ECU by using the signals received
from the crankshaft RPM sensor.
3. Camshaft RPM sensor
1) The camshaft RPM sensor controls the intake
and exhaust valve of the engine. It revolves at
60068042311 EN - 07/2021 - 01 10-97

Diesel engine
the half of the crankshaft speed and determines
whether the camshaft position is at the compres-
sion stage or the exhaust stage when the piston
is moving toward the top dead point. This infor-
mation cannot be determined by the crankshaft
RPM sensor. However, while the engine is nor-
mally operating, the information given by the
crankshaft RPM sensor is enough to define the
engine state. It means that the ECU receives in-
formation of the engine from the crankshaft RPM
sensor if the camshaft RPM sensor cannot
sense the engine state while the vehicle is run-
ning.
4. Accelerator pedal sensor
1) The accelerator pedal sensor sends the data
generated when a driver presses the accelerator
pedal to the ECU. The voltage value is gener-
ated by the potentiometer in the accelerator ped-
al sensor. The pedal position is calculated with
the programmed characteristics curves.
5. Fuel temperature sensor
1) This sensor measures the fuel temperature in
the fuel pump.
6. Boost pressure and temperature sensor
1) The boost pressure and temperature sensor
is connected to the intake stake via the O-ring. It
measures the absolute pressure and tempera-
ture in the intake stake.
2) The output signal is input to the ECU and the
boost pressure is calculated based on the ECU-
programmed characteristics curves.
7. Oil pressure sensor
1) The engine oil pressure sensor senses the
pressure of engine oil and sends the data to the
ECU.
8. Common rail pressure sensor
1) It is installed at the end of the common rail,
measuring the instantaneous internal pressure
of the common rail.
9. Engine coolant temperature sensor
1) The engine coolant temperature sensor per-
ceives the temperature of the engine coolant
sends the data to the ECU.
The injection characteristics of the common rail
are as follows.
1. Comparing to the existing injection character-
istics, the common rail requires the ideal fuel in-
jection as follows. The fuel injection amount and
the injection pressure work independently from
each other, satisfying conditions for all engines.
10-98 60068042311 EN - 07/2021 - 01

Diesel engine
2. It should be available to adjust the injection
amount to low for the ignition delay time, i.e., the
period from starting fuel injection to starting
combustion at the early stage of fuel injection.
3. The common rail system is a modulized sys-
tem. Generally, the following components take
key roles of the injection characteristics.
1) Injector solenoid valve installed on the cylin-
der head
2) Common rail
3) Fuel high-pressure pump
4) Electronic Control Unit (ECU)
5) Crankshaft RPM sensor
Injection Pipe
 Fuel high-pressure pipe
1) The fuel high-pressure pipe transfers high-
pressured fuel of 1,800 bar. Therefore, special
materials are used for fuel line to stand the max-
imum pressure of the system and the high-pres-
sure changes which are generated while fuel is
injected. The high-pressure pipe uses both the
external diameter of Ø6.35 and the bore of Ø3.0.
In addition, the length of the fuel high-pressure
pipes between the common rail and the injector
should be identical and installed as short as pos-
sible.
 Common rail 
A. Fuel injection pump

B Injector
C Common rail
D. Pressure sensor
E. Fuel supply fuel injection pipe
F. Fuel injection pipe for injector #1
G. Fuel injection pipe for injector #2
H. Fuel injection pipe for injector #3
I. Fuel injection pipe for injector #4
J. Fuel return hose
NOTE
The front engine direction (F) is the water pump

direction and the rear engine direction (R) is the
1) After the injector has used fuel from the com-
mon rail for fuel injection, the pressure in the
common rail is actually kept consistently. The
60068042311 EN - 07/2021 - 01 10-99

Diesel engine
fuel pressure is measured by the common rail
pressure sensor and kept as a desired value by
the pressure adjustment valve. The pressure
control valve controls the fuel pressure up to
1,800 bar in the common rail.
2) The common rail stores the fuel pumped from
the high-pressure fuel pump at the high pres-
sure. After the injector has used fuel from the
common rail for fuel injection, the pressure pul-
sation in the common rail is actually kept consis-
tently because of the volume of the common rail.
The fuel pressure is measured by the common
rail pressure sensor and kept as a desired value
by the pressure adjustment valve. The pressure
control valve controls the fuel pressure up to
1,800 bar in the common rail.
3) Doosan's common rail fuel injection system
separates the high-pressure apparatus from the
fuel injection apparatus. The ECU decides the
fuel amount and the fuel injection timing and
pressure for the optimum performance and in-
jects fuel in the cylinder.
Common Rail Disassembly


the common rail.
CAUTION
Do not reuse fuel injection pipes
and clamp; replace them with new
ones.If fuel injection pipes and
clamp are reused it may allow for-
eign substances into the fuel pipes
or cause oil leaks from bolt clamp-
ing and cause a critical fault in
engine performance.
10-100 60068042311 EN - 07/2021 - 01

Diesel engine

manifold.
Common Rail Assembly

NOTE
while attaching it.
2.2 kgf·m.

by hand.
60068042311 EN - 07/2021 - 01 10-101

Diesel engine
NOTE
kgf·m.
Common Rail Check

1. Check if there is any damage on the exterior
of the common rail.
2. Check whether there is any damage of the
pressure sensor of the common rail.
3. Check if there is any damage of the fuel pres-
sure restrict valve.
10-102 60068042311 EN - 07/2021 - 01

Diesel engine
Fuel injection pump

General Information
1 High pressure fuel line outlet 3 Low pressure fuel line inlet
2 High pressure fuel line return inlet 4 Drive shaft
Fuel high-pressure pump uses a radial piston

pump to generate high pressure in fuel. Pres-
sure is independently generated as fuel is injec-
ted. The RPM of the fuel high-pressure pump is
directly connected to the engine rotation speed
regardless of the rotation ratio of the transmis-
sion.
Comparing to the existing injection system, the
common rail injection system shows the consis-
tent fuel delivery amount. The injector is connec-
ted to the common rail with the high-pressure
pipe. It consists of a nozzle and a solenoid
valve. When a key switch is operated, actuating
60068042311 EN - 07/2021 - 01 10-103

Diesel engine
power is supplied to the solenoid valve by the
ECU. When the key switch is blocked, the sole-
noid valve ends injection.
Solenoid valve switching (open/close) is operat-
ed by high pressure and high current. Based on
the values set in the ECU, the solenoid valve of
the injector is sequentially operated. The crank-
shaft sensor and the camshaft sensor use to de-
tect the engine rev count for starting fuel injec-
tion and adjusting the injection timing.
The fuel high pressure pump pressurizes fuel at
the pressure of 1,800 bar and the pressurized
fuel is delivered to the common rail through the
high-pressure line.
The fuel high-pressure pump consists of the fol-
lowing components.
1. Functions
1) The fuel high pressure pump has two pres-
sure phase processes: low-pressure phase and
high-pressure phase. Under all operating condi-
tions, it transfers high-pressure fuel in a vehicle
for the entire service lifetime. In addition, it deliv-
ers fuel required to respond to the rapidly-
changing pressure in the common rail or quick
start of a vehicle. The fuel high pressure pump
continuously generates the system pressure
necessary for the common rail.
2. Configuration of fuel high pressure pump
1) Inside of the fuel high pressure pump, there
are three pump pistons and the pistons are in-
stalled with 120, compressing fuel to the circum-
ferential direction. Compression strokes occur
three times per rotation. Therefore, consistent
stress is kept in the pump driving apparatus and
low driving force is required. Pump driving force
of the common rail requires about 1/9 of that of
the existing pump system.
3. Operation method
1) The fuel delivery pump delivers fuel from the
fuel tank to the fuel high pressure pump through
the fuel inlet and the safety valve. Then the fuel
high pressure pump pumps and the transfers the
fuel to the lubricating and cooling circuit of the
high pressure pump through the safety valve.
The driving shaft, which has the eccentric cam,
moves the pump piston up and down according
to the cam shape.
2) When the transfer pressure of the fuel deliv-
ery pump exceeds the open pressure of the
safety valve, the fuel is transferred to the intake
stroke position of the pumping chamber where
the pump piston moves up and down through
the intake valve of the fuel high pressure pump.
10-104 60068042311 EN - 07/2021 - 01

Diesel engine
When the pump piston exceeds the bottom dead
point, the valve inlet is closed and fuel cannot be
transferred from the pumping chamber. So the
fuel is compressed over the delivered pressure.
3) As soon as the fuel pressure reaches the
common rail pressure, the outlet valve is
opened. Then the compressed fuel flows into the
high pressure circuit. The pump piston continu-
ously transfers fuel until it reaches the bottom
dead point. After the bottom dead point is
reached, the outlet valve is closed. The fuel in
the pumping chamber is relaxed and then the
pump piston moves down again. When the pres-
sure in the pumping chamber is lower than the
pressure of the fuel delivery pump, the inlet
valve is opened again and the above procedure
is started again.
4. Fuel supply collection
1) The fuel high pressure pump is designed to
deliver a lot of fuel. While the engine runs at idle
or partial load, the fuel excessively delivered re-
turns to the fuel tank through the pressure ad-
justment valve.
Disassembly of Fuel Injection Pump


quadrangular tool).
60068042311 EN - 07/2021 - 01 10-105

Diesel engine

NOTE

auto tensioner.
speed sensor.
NOTE

ones.
10-106 60068042311 EN - 07/2021 - 01

Diesel engine
 Remove the fuel injection pump. 

2) Remove the fuel injection pump.
3) Loosen the flange hex nut.
4) Remove the collar.
5) Remove the O- ring from the collar.
NOTE
Do not reuse the O-ring; replace with a new

one. Reuse of the O-ring may cause critical
damage to engine performance to occur.
Assembly of Fuel Injection Pump

 Attach the fuel injection pump. 
1) Mount the O- ring to the collar.

2) Mount the collar.
NOTE
● Ensure that you are attaching the injection
pump drive gear so that its engraving faces
the outside of the cylinder block.
● Ensure that the pin direction is the opposite
direction of the idle gear.
3) Tighten the flange hex nuts at a tightening tor-
que of 8.2 ±0.5 kgf·m.
4) Attach the fuel injection pump.
injection pump drive gear engravings.
NOTE
You can see two injection pump drive gear en-

gravings and one idle gear engraving.
NOTE
● Ensure that the idle gear engraving is posi-
tioned between the two injection pump drive
gear engravings.
● Align the injection pump drive gear engrav-
ings, the idle gear engraving, and the pin of
the fuel injection pump shaft before attaching
them.
6) The backlash between the fuel injection pump
and the idle gear is 0.087 ~ 0.2 mm.
60068042311 EN - 07/2021 - 01 10-107

Diesel engine

fuel injection pump and 0.087 ~ 0.2 mm
the idle gear

que of 2.2 kgf·m.

NOTE

wheel.
NOTE
Apply as follows and use TB121H equivalent

product.Apply to the surface of TGC cover with
sembly jig.
10-108 60068042311 EN - 07/2021 - 01

Diesel engine
NOTE
taching it.
one.
taching it.
dry cloth.
Ø2.5 ±0.5 mm.
NOTE
parts.
tach it.
2.2 kgf·m.
en the fixing bolt.
60068042311 EN - 07/2021 - 01 10-109

Diesel engine

tach it.
of 26 kgf·m.
NOTE

the auto tensioner.
quadrangular tool).
wise.
NOTE

Driving Units”.
10-110 60068042311 EN - 07/2021 - 01

Diesel engine
Intake/exhaust system
Turbocharger
General Information
1 Exhaust pipe 6 Intake stake

2 Turbine housing 7 Air inlet
3 Turbine wheel and shaft assembly 8 Oil outlet
4 Compressor housing 9 Exhaust gas outlet
5 Compressor wheel
Turbocharger increases the engine output by in-

haling high-density air to the cylinder by using
the exhaust heat energy of the engine.
1. The engine output is determined by fuel
amount and engine efficiency.
2. To combust the delivered fuel completely and
convert it to the useful work of the engine,
60068042311 EN - 07/2021 - 01 10-111

Diesel engine
enough air to completely combust the fuel
should be delivered to the cylinder.
3. Actually, the engine output is determined by
the capacity of the cylinder. If air is compressed
and delivered to the cylinder, the amount of air
in the cylinder is increased as much as com-
pressed. Therefore, more fuel can be combus-
ted and the engine output can be increased.
4. Supercharger is to compress air and deliver
the compressed air to a cylinder of an engine
and Turbocharger is a forced induction device
that forces more intake air, proportionately more
fuel, into the combustion chamber and super-
charges the exhaust gas energy into the atmos-
phere.
5. The key functions of a turbocharger are as fol-
lows.
1) Turbine: Kinetic energy of the exhaust gas
from the combustion chamber passes through
the turbine housing and is captured by the tur-
bine blades, transferring the turning force to the
turbine shaft. Turbine refers to the device where
this operation is generated. A turbine has seal-
ings and the heat screen to protect bearings
from harmful impact of exhaust gas.
2) Compressor: A compressor is connected to a
shaft where the turbine is connected, composing
a rotor assembly. It uses the turning energy from
the turbine shaft to inhale and compress air, and
then transfers the compressed air to the intake
stake. This is the performance property of a
compressor.
3) Bearing system:
● Thrust bearing: Shaft force acts upon the tur-
bine wheel. The thrust bearing prevents a
shaft from being moved by the shaft force.
● Journal bearing: Journal bearings are floating
types. They create a doubled-oil film on the
exterior and interior of the bearing,
● allowing the bearing to spin independently.
The doubled oil film works as a buffer reduc-
ing the sliding speed on the surface of the
bearing lower than the shaft spinning speed,
aiming dynamic stability.
4) Sealing of compressor shaft: A seal plate and
seal ring compose a dual structure to prevent
the compressed intake air and lubricating oil
from leaking.
Failure Diagnosis
Noise or vibration Rotating part is contacted Repair or replace it
10-112 60068042311 EN - 07/2021 - 01

Diesel engine
Unbalanced rotation of a rotor Repair or replace it

Burn Repair or replace it
Loose joint Check or repair it
Deformed or damaged intake
Replace it
unit hose
Poor clamping state Adjust and tighten the clamp
Replace and check if the impel-
Contaminated or damaged air fil-
ler of the turbocharger is dam-
ter
aged
Leakage of coolant from the tur-
Replace the hose and the gasket
bocharger or oil from the oil hose
Leakage of gas from the exhaust Replace the gasket or tighten the
manifold fixing nut
Poor turbo actuator operation Replace the turbocharger
Leakage from the engine block
Check the engine
and the exhaust manifold
Contaminated blow by gas and Check the turbo impeller and the
abnormal oil amount turbo intake outlet
Large gap of the turbocharger
Check if there is any sand or
wheel, causing interference with
metallic foreign substance
the wall
Damaged turbocharger wheel
Damaged wheel and shaft of the Check if there is any sand or
turbocharger metallic foreign substance
Poor rotating force of the turbo- Check if there is any sand or
charger wheel metallic foreign substance
Leakage of gas from each part of
Check or repair it
the exhaust system
Clogged air filter element Replace or clean it
Contaminated or damaged tur-
Repair or replace it
bocharger
Leakage of air from the discharg-
Check or repair it
ing part of the compressor shaft
Replace it
unit hose
ter
Lowered output aged
Check the engine
the wall
60068042311 EN - 07/2021 - 01 10-113

Diesel engine

Replace it
unit hose
Oil leakage ler of the turbocharger is dam-
ter
aged

Check the engine
Oil leakage the wall
Check the engine
Oil consumption Large gap of the turbocharger
the wall

Replace it
unit hose
Black and white emissions ter
aged
10-114 60068042311 EN - 07/2021 - 01

Diesel engine
the wall
Blue emissions Check the engine
Oil leakage to the turbine or
compressor
Too much fog
Worn or damaged seal ring due
to worn bearing
Clogged air filter element Replace or clean it
Clogged air duct Check or repair it
Air leakage from the intake sys-
Check or repair it
tem
The turbocharger cannot rotate
Too much exhaust emissions Repair or replace it
because of burning
A turbine blade or compression
wing contacts with the other one Repair or replace it
or is damaged
Deformed or clogged exhaust
Check or repair it
system pipe
How to Maintain Turbocharger

1. Cautions for engine operation 1) Observe the followings when starting, operat-
ing, and stopping an engine.
Item Cautions Reasons

Check the oil amount
Therefore, start the engine with
Overhasty start of engine leads
the starter motor to check the
to engine rotation without lubri-
rise of oil pressure (until the gra-
cating turbocharger and other
dation of the oil pressure gauge
engine parts, causing abnormal
moves or the pressure indicator
wear or burning of bearings.
lamp is turned on).
If you replace oil, oil filter car-
Starting an engine tridge, or lubrication system
parts or use an engine in cold
areas, or the engine has stopped
When an engine has stopped or
for a long period, loosen the oil
kept cold for a long period, circu-
pipe joint at the inlet of the turbo-
lation of oil in the pipe gets poor.
charger and run the starter motor
until oil flows out. After complet-
ing the work, tighten the oil pipe
joint again and start the engine.
60068042311 EN - 07/2021 - 01 10-115

Diesel engine
When the engine is suddenly

loaded while the engine and the
Operate the engine at idle for turbocharger have not been
five minutes from starting it. smoothly rotated after starting
the engine, parts with insufficient
After starting an engine oil may be burnt.
Leakage of oil, gas, or air (espe-
Check if oil, gas, or air is leaked
cially oil) reduces oil pressure
from each part. If so, take proper
and loss of oil cause burning of
action.
bearings.
check the following.
Too low oil pressure causes ab-
Oil pressure At idle: 1.5 ~ 3.0
2 normal wearing or burning of
kg/cm Fully loaded: 3.0 ~ 5.5
2 bearings. Too high oil pressure
kg/cm
During Operation causes oil leakage.
When abnormal noise or vibra-
Operating an engine with noise
tion occurs, slowly reduce the ro-
or vibration may cause irreversi-
tate count until the engine stops
ble damage of the engine.
and then figure out the causes.
Sudden engine stop after operat-
ing the engine under high load
allows the heat from the red-
Operate the engine at idle for
Stopping an Engine heated turbine blade to be deliv-
five minutes before stopping it.
ered to the bearing system. Then
oil burns and the bearing metal
and rotation shaft are burnt.
2. Cautions for Maintenance of bearings may determine the turbocharger life-

time. Please use only recommended genuine
1) When the RPM is rapidly increased after
engine oil and check and replace the engine oil
starting the engine, the journal bearings in the
periodically.
crankshaft is excessively rotated, the crankshaft
is rotated at excessive speed before the journal 6) Prolonged usage of contaminated air cleaner
bearing of the crankshaft is lubricated fully. If the may cause a critical damage of the turbocharg-
turbocharger rotates in this situation, bearings er. Regularly check and replace the air cleaner.
are not smoothly cooled and lubricated, causing
7) A turbocharger is a very complex and precise
bearing burn and damage of the related parts.
part. Only certified and skilled technicians
2) Please operate the engine for two minutes or should work on it.
more in order to lubricate the turbocharger fully
8) If a turbocharger is operated without intake
after replacing the engine oil or oil filter.
and exhaust pipe, serious human injury may oc-
3) If an engine has been operated at high speed cur and critical faults of the engine performance
for a long period, fully operate the engine at idle may occur. Please operate a turbocharger only
and then stop the engine. Otherwise, the turbine when all of parts are exactly mounted on the
wheel continuously runs without oil pressure in specified position.
the turbocharger. Therefore, no oil film is cre-
9) Do not lift up a turbocharger by grabbing the
ated on the center bearings and the journal
actuator. The actuator may be damaged be-
bearings of the turbocharger, causing bearing,
cause of the weight of the turbocharger.
wearing out and shortening of the turbocharger
lifetime. 10)The weight of a turbocharger is about 4.0 kg
or more. To lift up a turbocharger for installing or
4) If an engine is not operated for a long period
removing it, the worker should lower the center
during cold weather or in areas with cold cli-
of gravity or press his body close to the turbo-
mate, operate the engine at idle after starting the
charger. Otherwise, worker may drop the turbo-
engine until the engine oil pressure is normal.
charger, causing damage of the part and injury.
5) The turbocharger turbine spins at high speed
of 50,000 ~ 200,000 rpm. Therefore, lubrication
10-116 60068042311 EN - 07/2021 - 01

Diesel engine
Turbocharger Disassembly


oil delivery pipe.
Turbocharger Check
1. Routine Check and Repair: The turbocharger
performance is determined by maintenance
state of the engine. So you should regularly per-
form inspection and check as specified.
1) Intake system: For the intake system, the air
filter should be carefully managed. For a wet
type air filter, if the oil amount is lower than the
specified amount, filtering efficiency is lowered.
On the contrary, if it is too high, the filter absorbs
oil and contaminates the case. Especially, when
the rotor is contaminated, the precisely adjusted
balance is broken, causing vibration. In addition,
the bearings are overloaded, resulting in bearing
burn and abnormal wearing. Therefore, an air fil-
ter should be carefully used and maintained ac-
cording to the instructed and specified ways. For
60068042311 EN - 07/2021 - 01 10-117

Diesel engine
a dry type air filter, the intake resistance should
be small as possible.
2) Exhaust system: For the exhaust system,
when exhaust gas leaks from the exhaust pipe
or turbocharger joint, supercharging efficiency is
lowered. So you need to pay attention to prevent
gas leakage and burn. Heat resistant nuts are
used for parts which are highly heated during
operation, such as turbine seal, and the nuts
should not be mixed with other nuts. The screw
burn prevention paint should be applied to the
assembly nuts of the specified positions.
3) Lubrication system: For the lubrication sys-
tem, be careful with the oil quality and the re-
placement time of the cartridge of the oil filter.
Degradation of engine oil has bad effect on the
turbocharger, as well as the engine body.
2. Regular Inspection and Repair: The state and
contamination of a turbocharger should be
checked regularly.
1) How to check the rotating state of a rotor as-
sembly: You can check the rotating state of a ro-
tor assembly by checking the abnormal sound
which occurs while the solid of rotation is rotat-
ing. If you use a sound rod, contact the neb of
the sound rod to the turbocharger housing and
slowly raise the RPM. If high-pitched sound con-
tinues, it means that the state is abnormal. In
this case, the bearing or the rotor assembly may
be abnormal. So you need to replace or repair
the turbocharger.
2) How to detach and check the turbocharger:
Detach the turbocharger from the engine and
clean or check it. At this time, seal the oil inlet
and outlet with sealing tape.
3) Cautions for attaching the turbocharger to the
engine: Please observe the following precau-
tions as attaching the turbocharger to the engine
and handling it after attaching. Especially, be
careful not to let foreign substances flow into the
turbocharger.
● Lubrication system: Before attaching the tur-
bocharger to the engine, inject new oil into the
oil inlet and spin the turbine shaft to lubricate
journal bearings and thrust bearings. Cleanse
the pipes from starting from the engine to the
oil inlet and outlet and check if there is any
damage of the pipes or foreign substance in
the pipe. Precisely connect the oil pipes to
prevent oil leaks.
● Intake system: Check if there is any foreign
substance within the intake system. Precisely
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Diesel engine
attach the intake system to the engine to pre-
vent air leaks from the joints of the intake sys-
tem and the air filter.
● Exhaust system: Check if there is any foreign
substance in the exhaust system. The heat-
resistant bolts and nuts should be used. Do
not use any of general nuts and bolts. Apply
burn prevention paint to the bolts and nuts.
Precisely attach the exhaust system to the
engine to prevent gas leaks from the exhaust
system joints.
Turbocharger Assembly

turbocharger.
que of 1.0 kgf·m.
exhaust manifold.
NOTE
ing the gasket.
mounting it.
que of 2.2 kgf·m.
NOTE

of 1.9 kgf·m.
NOTE
bocharger side.
60068042311 EN - 07/2021 - 01 10-119

Diesel engine

NOTE

Disassembly of EGR


oil delivery pipe.
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Diesel engine

NOTE
Exhaust gas make engine parts extremely hot.

Only remove the parts when they have fully
cooled to prevent burns.

Assembly of EGR

take manifold.
NOTE

que 2.2 kgf·m.
60068042311 EN - 07/2021 - 01 10-121

Diesel engine
NOTE
ing the EGR cooler.
mounting it.
que of 3.1 kgf·m. (exhaust manifold side)
que of 2.2 kgf·m. (cylinder head side)
NOTE


turbocharger.
que of 1.0 kgf·m.
exhaust manifold.
NOTE
ing the gasket.
mounting it.
que of 2.2 kgf·m.
NOTE

of 1.9 kgf·m.
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Diesel engine
NOTE
bocharger side.

NOTE

Intake manifold
Disassembly of Intake Manifold
 Disconnect the throttle valve (ACV) and the 
intake stake.
2) Remove the throttle valve (ACV) from the in-
take stake.
4) Remove the intake stake from the intake
manifold.
60068042311 EN - 07/2021 - 01 10-123

Diesel engine


(A).

the common rail.
NOTE
ance.
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Diesel engine

manifold.

NOTE

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Diesel engine
 Remove the intake manifold. 

2) Remove the intake manifold and the gasket.
4) Remove EGR mixer and gasket.
Assembly of Intake Manifold

 Attach the intake manifold. 
1) Mount the intake manifold and the gasket.
NOTE
ing the gasket.
mounting it.
2) Tighten 11 flange hex bolts and 2 flange hex
bolts at a tightening torque of 2.2 kgf·m.
3) Attach EGR mixer and gasket to the intake
manifold.
que 2.2 kgf·m.

filter module.
the cylinder block.
NOTE
ted.
mounting them.
que of 2.2 kgf·m.
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Diesel engine
mounted clean.
hand.

take manifold.
NOTE

que 2.2 kgf·m.
NOTE
while attaching it.
2.2 kgf·m.
60068042311 EN - 07/2021 - 01 10-127

Diesel engine

by hand.
NOTE
kgf·m.

NOTE
the hose.
NOTE

the engine.
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Diesel engine
hose.
of 1.0 kgf·m.
NOTE

NOTE

 Connect the throttle valve (ACV) and the in- 
take stake.
1) Mount the intake stake to the intake manifold.
NOTE
ing the gasket.
mounting it.
2.2 kgf·m.
3) Assemble the throttle valve to the intake
stake.
NOTE
ing the gasket.
mounting it.
2.2 kgf·m.
60068042311 EN - 07/2021 - 01 10-129

Diesel engine
Exhaust manifold
Disassembly of Exhaust Manifold


oil delivery pipe.

DANGER
vent burns.
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Diesel engine

3) Loosen 2 flange hex bolt, 2 space bolt and 2
flange hex nut.
 Remove the exhaust manifold. 

2) Remove the exhaust manifold and the gasket.
DANGER
vent burns.
Assembly of Exhaust Manifold

 Attach the exhaust manifold. 
1) Mount the gasket so that the TOP mark faces

the top surface and the front of the engine.
2) Attach the exhaust manifold.
que 3.1 kgf·m.
60068042311 EN - 07/2021 - 01 10-131

Diesel engine
 Attach the heat screen. 
 1) Temporarily tighten 2 hex bolts to the ex-

haust manifold side.
 2) Mount the heat screen.
 3) Tighten 2 hex bolts.
 4) Tighten 4 flange hex bolts at a tightening
torque 1.25 kgf·m.
NOTE
● Be careful to note the direction in which the
gasket is mounted. Mount the gasket so that
the TOP mark faces the front of the engine.
mounting it.

2) Tighten 2 flange hex bolt, 2 space bolt and 2
flange hex nut as a tightening.
que of 2.2 kgf·m.
NOTE
NOTE
ing the EGR cooler.
mounting it.
que of 3.1 kgf·m. (exhaust manifold side).
que of 2.2 kgf·m. (cylinder head side).
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Diesel engine
NOTE


turbocharger.
que of 1.0 kgf·m.
exhaust manifold.
NOTE
ing the gasket.
mounting it.
que of 2.2 kgf·m.
NOTE

of 1.9 kgf·m.
NOTE
bocharger side.
60068042311 EN - 07/2021 - 01 10-133

Diesel engine

NOTE

Intake stake
Disconnection of Glow Plug

the common rail.
NOTE
ance.
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Diesel engine

manifold.
 Disconnect the glow plugs 

Connection of Glow Plug


at a tightening.
4) Mount 4 washers.
1.3 ~ 2 N·m.
60068042311 EN - 07/2021 - 01 10-135

Diesel engine
NOTE
while attaching it.
2.2 kgf·m.

by hand.
NOTE
kgf·m.
Cylinder block/cylinder head

General information
Doosan's diesel engine is an air-cooled electron- The high-pressure fuel generated from the fuel
ic control diesel engine that uses cooling fans, high-pressure pump is stored in the common
overhead valve, and turbocharger. rail. When a driver operates the vehicle, fuel
10-136 60068042311 EN - 07/2021 - 01

Diesel engine
injection timing and optimum fuel amount are The forged crankshaft is an integral structure.
decided based on the data set in the Electronic The oil seals of the crankshaft and the Drive
Control Unit (ECU) and the solenoid valve of the Plate prevents oil from permeating into the Drive
injector installed in each engine cylinder is oper- Plate housing.
ated to inject fuel into the cylinder.
The connecting rod is forged and its big end part
The cylinder block is made out of cast iron alloy vertically separated. Like a piston, the connect-
and an anti-vibration and anti-noise crank case ing rod can be disassembled through the upper
is mounted. In addition, the cylinder block and side of the cylinder. The alloy-type prefabricated
the timing gear case are designed as an integral bearing is used for the active part of the crank-
structure to reduce the engine length and im- shaft and the connecting rod.
prove tightness. The cylinder head is an integral
structure, too.
Cylinder block
Disassembly of Cylinder Block
1. Detach the cylinder block.
NOTE
Refer to chapter entitled “Procedure of Disas-

sembling an Engine”.
Assembly of Cylinder Block

1. Attach the cylinder block.
NOTE
Refer to chapter entitled “Procedure of Assem-

bling an Engine”.
Check of Cylinder Block

1. Cleanse the cylinder block and check if there
is any cracked or damaged part with naked eye.
2. Replace the cylinder block if it is seriously
cracked or damaged. Repair tiny cracks if exist-
ing.
3. Check if the oil path or coolant path is clogged
or corroded.
4. Perform the hydrostatic test to check whether
there is a crank or an air leakage.
5. Block the discharging outlets of the cooling
water path and the oil path of the cylinder block
and put pressure of 4 kg/cm2 on the inlet. Then
sink the cylinder block in the 70 °C water for 1
minute and check if air leaks.
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Diesel engine
Measurement of Inside Diameter of Main 
Bearing Bore of Cylinder Block
1. Assemble the cylinder block and the crank
case.
2. Set the gauge.
3. Remove the foreign substances from the main
bearing bore of the cylinder block.
4. Measure the inside diameter of the main bear-
ing bore of the cylinder block.
1) For 5ea main bearings (D) of the cylinder
block, measure 10 points of the bearings: front
and rear.
2) Measure three (A, B, and C) points of the
main bearing part of the cylinder block.
3) The standard measurement value of the in-
side diameter of the main bearing bore of the
cylinder block is within the ange of 62.0 ~
62.021 mm.

Cylinder Block Inside
diameter of main bear- 62.0 ~ 62.021 mm
ing bore
Measurement of Inside Diameter of Piston 

Bore of Cylinder Block
1. Set the gauge.
2. Remove the foreign substances from the pis-
ton bore of the cylinder block.
3. Measure the inside diameter of the piston
bore of the cylinder block.
1) For 4ea piston bores of the cylinder block,
measure total 12 points of the piston bores: top,
middle, and bottom.
2) Measure 2 points of A and B on the piston
bore of the cylinder block.
side diameter of the piston bore of the cylinder
block is within the range of 89.990 ~ 90.010 mm.

Cylinder Block Piston
89.990 ~ 90.010 mm
bore inside diameter
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Diesel engine
Measurement of Inside Diameter of Cam- 
shaft Bearing of Cylinder Block
1. Set the gauge.
2. Remove the foreign substances from the
camshaft bearing shell of the cylinder block.
3. Measure the inside diameter of the camshaft
bearing of the cylinder block.
1) For 3ea of the cylinder block, measure total 6
points of the camshaft bores: front and rear.
2) Measure 3 points (A, B, and C) of camshaft
bearing shells of the cylinder block.
side diameter of the camshaft bearing of the cyl-
inder block is within the range of 45.0 ~ 45.025
mm.

Cylinder Block Cam-
shaft bearing inside di- 45.0 ~ 45.025 mm
ameter
Cylinder head
Disassembly of Cylinder Head
1. Detach the cylinder head.
NOTE
Refer to Chapter entitled “Procedure of Disas-

Assembly of Cylinder Head

1. Attach the cylinder head.
NOTE
Refer to Chapter entitled “Procedure of Assem-

bling an Engine”.
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Diesel engine
Check of Cylinder Head
 Remove carbon from the bottom surface of
the cylinder head.
NOTE
Be careful not to scratch the valve seat surface.

 For cracks or damage which cannot be
checked with naked eye, perform the hydro-
static test or the magnetic particle testing.
 Check if the cylinder head is warped. 
1) Check 6 directions from A to F with the scale

and the gap gauge.
 Check flatness of the cylinder head. 
1) Measure flatness of the intake assembly sur-

face and the exhaust assembly surface of the
cylinder head with the scale and the gap gauge.
 Perform the hydrostatic test.
1) Block the discharging outlets of the cooling
water path and the oil path of the cylinder head
and put pressure of 4 kg/cm2 on the inlet. Then
sink the cylinder head in the 70 °C water for 1
minute and check if air leaks.
Valve
Disassembly of Valve
1. Remove the valve.
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Diesel engine
NOTE

Assembly of Valve
1. Mount the valve.
NOTE

bling an Engine”.
Measurement of Inside Diameter of Valve

Guide
 Mount the valve guide to the cylinder head.
 Set the meter.
 Measure the inside diameter of the valve 
guide.
1) Measure total 6 points of the valve guide to
the vertical direction (B) and the horizontal direc-
tion (A): top, middle, and bottom.
2) Measure 16ea valves; 8ea intake valves and
8ea exhaust valves.
3) The standard measurement value of the valve
guide inside diameter is within the range of 7.0 ~
7.015 mm.

Valve guide inside di-
7.0 ~ 7.015 mm
ameter
Measurement of Valve Stem End

 Mount the valve to the cylinder head.
 Perform the zero point adjustment of the me-
ter.
60068042311 EN - 07/2021 - 01 10-141

Diesel engine
 Measure the valve stem end (A). 
1) Measure 8ea intake valve stem ends.

take valve stem end is within the range of 17.0 ~
17.5 mm.
3) Measure 8ea exhaust valve stem ends.
4) The standard measurement value of the ex-
haust valve stem end is within the range of 17.1
~ 17.6 mm.

Intake valve stem end 17.0 ~ 17.5 mm
Exhaust valve stem
17.1 ~ 17.6 mm
end
Measurement of Valve Step Height

 Measure the height of the contact surface of
the intake and exhaust valve. If the measure-
ment value is over the allowable limit, it
means that the valve seat is worn. Replace
the valve seat.
 Measure the valve step height. 
1) Put the valves in the valve seat of the cylinder

head and measure how deep the valves have
been put from the cylinder head bottom surface
with the dial gauge.
2) Measure 4 points (A, B, C, and D) of the
valve.
take valve is within the range of 0.6 ~ 0.9 mm.
4) The standard measurement value of the ex-
haust valve is within the range of 0.9 ~ 1.2 mm.

Intake Valve Step
0.6 ~ 0.9 mm
Height
Exhaust Valve Step
0.9 ~ 1.2 mm
Height
Measurement of Gap between Piston and

Valve
 Detach the cylinder head.
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Diesel engine
 Prepare measurement of the gap between the 
piston and the valve.
1) Prepare the lead with thickness of 3mm.
2) Position the greased lead on total 16 points
(A, B, C, and D) on the top of each piston.
3) Attach the cylinder head.
4) Rotate the crankshaft pulley in order to move
the piston.
5) Detach the cylinder head.
 Measure the gap between the piston and the
valve.
1) Measure thickness of the lead with the vernier
calipers.
2) The standard value of gap between the piston
and the intake valve is within the range of 1.12 ~
2.29 mm.
3) The standard value of gap between the piston
and the exhaust valve is within the range of 1.44
~ 2.58 mm.

Gap between the pis-
ton and the intake 1.12 ~ 2.29 mm
valve
Gap between the pis-
ton and the exhaust 1.44 ~ 2.58 mm
valve
Check of Valve Spring

 Check the exterior of the valve spring with
naked eye.
1) Check if the exterior of the valve spring is
damaged with naked eye. Replace it with a new
one if required.
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Diesel engine
 Check the free length of the valve spring. 
1) Measure the free length of the valve spring

with the vernier calipers.
NOTE
If the length is too small, replace the valve

spring with a new one.
 Check the valve spring squareness. 
A. Free length
B. Squareness
C Right-angle square
1) Measure the squareness of the valve spring
with the surface plate and the right-angle
square.
NOTE
If the measurement value is abnormal, replace

the valve spring with a new one.
 Check the tension of the valve spring. 
1) Measure the tension of the valve spring with

the spring tester (A).
NOTE
If the measurement value is abnormal, replace

the valve spring with a new one.
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Diesel engine
Rocker arm
Disassembly of Rocker Arm


(A).

the common rail.
60068042311 EN - 07/2021 - 01 10-145

Diesel engine
NOTE
and cause a critical fault in engine
performance.


NOTE

NOTE
left to right.
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Diesel engine



60068042311 EN - 07/2021 - 01 10-147

Diesel engine
Assembly of Rocker Arm

que of 2.2 ±0.22 kgf·m.

1 ±0.1 kgf·m.
NOTE

at a tightening.
4) Mount 4 washers.
1.3 ~ 2 N·m.
10-148 60068042311 EN - 07/2021 - 01

Diesel engine

NOTE
NOTE

4.35 ±0.35 kgf·m.

order.
60068042311 EN - 07/2021 - 01 10-149

Diesel engine

by hand.
NOTE
kgf·m.

NOTE
the hose.
NOTE

the engine.
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Diesel engine

NOTE

Check of Rocker Arm Shaft

 Remove the rocker arm shaft. 
1) Loosen and remove the fixing bolts from the

rocker arm bracket.
2) Remove the rocker arm bracket, the rocker
arm shaft spring, the rocker arm, and the rocker
arm shaft in the order as listed before.
 Check warpage of the rocker arm shaft. 
1) Put the rocker arm shaft on two V-blocks.

2) Install the dial gauge.
3) Check the degree of warpage of the rocker
arm shaft as rotating the rocker arm shaft.
NOTE
If the warpage is slight, correct it by pressing

with the press. If the warpage is out of the allow-
able limit, replace it with a new one.
60068042311 EN - 07/2021 - 01 10-151

Diesel engine
 Check the outside diameter of the rocker arm 
shaft.
1) Measure the outside diameter of the rocker
arm shaft on the position where the rocker arm
is attached with the outside diameter microme-
ter.
NOTE
If the outside diameter is out of the allowable

limit, replace it with a new one.
Check of Rocker Arm

1) Loosen and remove the fixing bolts from the

rocker arm bracket.
2) Remove the rocker arm bracket, the rocker
arm shaft spring, and the rocker arm in the order
as listed before.
 Check the exterior of the rocker arm with the
naked eye.
1) Check whether the adjust screw cap assem-
bly surface, which moves as contacting to the
valve stem, is scratched, or the layer is worn
with the naked eye.
NOTE
● If the wear is slight, polish it with the oil-con-
tained whetstone or fine sandpaper. If the lay-
er is seriously worn, replace the rocker arm
with a new one.
● For polishing the rocker arm, use the sandpa-
per dipped in oil.
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Diesel engine
 Measure the inside diameter of the rocker 
arm.
1) Measure the rocker arm inside diameter with
the micrometer or the vernier calipers.
2) Apply HLA & rocker arm bore A. (ø20)
NOTE
Compare the measurement value with the out-

side diameter of the rocker arm shaft. If the gap
is larger than the specified value, replace the
one of which wear is more serious.
Tappet and push rod

Disassembly of Valve Tappet
1. Detach the valve tappet.
NOTE

Assembly of Valve Tappet

1. Attach the valve tappet.
NOTE

bling an Engine”.
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Diesel engine
Check of Valve Tappet
 Check the exterior of the valve tappet with 
naked eye.
1) Check whether the valve tappet surface,
which moves as contacting to the camshaft, is
cracked or scratched.
NOTE
tained whetstone or fine sandpaper. If the
crack or scratch is serious, replace the valve
tappet with a new one.
● For polishing the camshaft, use the sandpa-
per dipped in oil.
 Measure the gap of the valve tappet.
1) Measure the outside diameter of the valve
tappet and the tappet hole diameter of the cylin-
der block.
NOTE
If the diameter is out of the allowable limit, re-

place the valve tappet with a new one.
 Measure the outside diameter of the valve 
tappet.
1) Measure the outside diameter of the valve
tappet with the outside diameter micrometer.
NOTE
If the diameter is out of the allowable limit, re-

place the valve tappet with a new one.
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Diesel engine
Disassembly of Push Rod


(A).

the common rail.
NOTE
ance.
60068042311 EN - 07/2021 - 01 10-155

Diesel engine


NOTE

NOTE
left to right.
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Diesel engine



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Diesel engine
 Remove the push rods. 
1) Remove the push rods.
Assembly of Push Rod

 Connect the push rods. 
1) Apply engine oil on both ends of the push

rods.
2) Connect the push rods in the cylinder head
holes.
3) Hit the head of the push rods with a rubber
hammer lightly once or twice to get them posi-
tioned in the tappet holes.
NOTE
After connecting the push rods, rotate them to

check the connection state.

que of 2.2 ±0.22 kgf·m.
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Diesel engine

1 ±0.1 kgf·m.
NOTE

at a tightening.
4) Mount 4 washers.
1.3 ~ 2 N·m.

NOTE
60068042311 EN - 07/2021 - 01 10-159

Diesel engine
NOTE

4.35 ±0.35 kgf·m.

order.

by hand.
NOTE
kgf·m.
10-160 60068042311 EN - 07/2021 - 01

Diesel engine

NOTE
the hose.
NOTE

the engine.

NOTE

60068042311 EN - 07/2021 - 01 10-161

Diesel engine
Check of Warpage of Push Rod
 Check warpage of the push rod. 
1) Put the push rod on the surface plate.

2) Measure the warped degree with the gap
gauge as rolling the push rod.

Warpage of push rod 0.5 mm
Camshaft
Disassembly of Camshaft
 Detach the camshaft.
NOTE

 Remove the camshaft gear (A). 
1) Heat the camshaft gear (A) at 180 ±10 °C.

2) Remove the camshaft gear (A) and the thrust
washer (C) from the camshaft (B).
NOTE
NEVER let the camshaft gear heat to a tempera-

ture exceeding 200 °C.
10-162 60068042311 EN - 07/2021 - 01

Diesel engine
Assembly of Camshaft
 Mount the cam gear (A). 
1) Mount the thrust washer (C) on the camshaft

(B).
2) Mount the woodruff key (D), heat the cam
gear (A) at the temperature of 180 ±10 °C, and
then press in the camshaft into the cam gear.
NOTE
● NEVER let the cam gear heat to a tempera-
ture exceeding 200 °C.
● The gear engraving should face outward.
 Attach the camshaft.
NOTE
Refer to Chapter entitled ”Procedure of Assem-

bling an Engine”.
Measurement of Camshaft Journal Outside

Diameter
 Set the gauge.
 Remove foreign substances from the cam-
shaft.
 Measure the outside diameter of the camshaft 
journal.
1) For 3ea camshaft journals, measure total 6
points of the outside diameters: front and rear.
2) Measure 2 points (vertical and horizontal) of
the outside diameters of the camshaft journals.
3) The standard measurement value of the out-
side diameter of the camshaft journal is within
the range of 44.919 ~ 44.93566 mm.

Camshaft journal 44.919~44.935 mm
NOTE
● If the outside diameter is out of the allowable
limit, replace the camshaft with a new one.
● Check whether the camshaft surface is
cracked or scratched.
tained whetstone or fine sandpaper. If the
crack or scratch is serious, replace the cam-
shaft with a new one.
● For polishing the camshaft, use the sandpa-
per dipped in oil.
60068042311 EN - 07/2021 - 01 10-163

Diesel engine
Measurement of Camshaft
 Check the camshaft offset. 
1) Move the camshaft gear to the opposite side

of the cylinder block.
2) Measure the gap between the thrust washer
and the camshaft gear with the gap gauge.

Camshaft offset 0.1 ~ 0.2 mm
NOTE
● Check if the gap is within the range of0.1 ~
0.2 mm.
● If the offset is too large, replace the thrust
washer with a new one.
 Measure warpage of the camshaft. 
1) Put the camshaft on two V-blocks.

2) Check the degree of warpage of the camshaft
with the dial gauge.
NOTE
If the warpage is out of the allowable limit, re-

place the camshaft with a new one.
10-164 60068042311 EN - 07/2021 - 01

Diesel engine
Timing gear case

Detaching Timing Gear Case

quadrangular tool).

NOTE

auto tensioner.
speed sensor.
NOTE

ones.
60068042311 EN - 07/2021 - 01 10-165

Diesel engine
Assembly of Timing Gear Case
NOTE
● Apply as follows and use TB121H equivalent
product.
● Apply to the surface of TGC cover with ø2.5
±0.5 mm thickness.
sembly jig.
NOTE
taching it.
one.
taching it.
dry cloth.
Ø2.5 ±0.5 mm.
NOTE
parts.
10-166 60068042311 EN - 07/2021 - 01

Diesel engine
tach it.
2.2 kgf·m.
en the fixing bolt.

tach it.
of 26 kgf·m.
NOTE

the auto tensioner.
quadrangular tool).
wise.
NOTE

fer to Belt Tension in Chapter entitled “Others/
Driving Units”.
60068042311 EN - 07/2021 - 01 10-167

Diesel engine
Flywheel housing
Disassembly of Flywheel Housing


 Remove the flywheel housing. 

2) Remove the flywheel housing.
10-168 60068042311 EN - 07/2021 - 01

Diesel engine
Assembly of Flywheel Housing
 Attach the flywheel housing. 
1) Align the flywheel housing to the pin and at-

tach it.
6.2 kgf·m.

torque.

option) ±4°
wheel
NOTE


4.4 kgf·m.
60068042311 EN - 07/2021 - 01 10-169

Diesel engine
Breather
Disconnection of Breather Hose

Connection of Breather Hose


NOTE

10-170 60068042311 EN - 07/2021 - 01

Diesel engine
Cylinder head cover

Disassembly of Cylinder Head Cover


(A).

the common rail.
60068042311 EN - 07/2021 - 01 10-171

Diesel engine
NOTE
and cause a critical fault in engine
performance.

manifold.

10-172 60068042311 EN - 07/2021 - 01

Diesel engine

NOTE

NOTE
left to right.
 Disconnect the glow plugs. 

60068042311 EN - 07/2021 - 01 10-173

Diesel engine

Assembly of Cylinder Head Cover


1 ±0.1 kgf·m.
NOTE

at a tightening.
4) Mount 4 washers.
1.3 ~ 2 N·m.
10-174 60068042311 EN - 07/2021 - 01

Diesel engine

NOTE
NOTE

4.35 ±0.35 kgf·m.

order.
60068042311 EN - 07/2021 - 01 10-175

Diesel engine
NOTE
while attaching it.
2.2 kgf·m.

by hand.
NOTE
kgf·m.
10-176 60068042311 EN - 07/2021 - 01

Diesel engine

NOTE
the hose.
NOTE

the engine.

NOTE

60068042311 EN - 07/2021 - 01 10-177

Diesel engine
Idle gear
Disassembly of Idle Gear

quadrangular tool).

NOTE

auto tensioner.
speed sensor.
NOTE

ones.
10-178 60068042311 EN - 07/2021 - 01

Diesel engine
 Remove the idle gear. 

2) Remove the idle gear shaft.
3) Remove the idle gear.
Assembly of Idle Gear

 Attach the idle gear. 
1) Apply engine oil to the inside of the idle gear

bush in the idle gear.
2) Attach the idle gear.
NOTE
Make sure that you are attaching the idle gear

so that its engraving faces the outside of the cyl-
inder block.
camshaft gear engravings.
Note) You can see two camshaft gear engrav-
ings and one idle gear engraving.
60068042311 EN - 07/2021 - 01 10-179

Diesel engine
NOTE
Make sure that the idle gear engraving is posi-

tioned between the two camshaft gear engrav-
ings.
between the idle gear engravings.
Note) You can see one crankshaft gear engrav-
ing and two idle gear engravings.
NOTE
Make sure that the crankshaft gear engraving is

positioned between two idle gear engravings.
5) Align the flange hex holes of the cylinder
block to those of the idle gear shaft.
6) Attach the idle gear shaft.
NOTE
Make the oil hole of the idle gear shaft face the
top surface of the cylinder block.
que of 4.4 kgf·m.
8) Backlash of the idle gear and the crankshaft
gear is 0.087 ~ 0.200 mm.
9) The backlash between the idle gear and the
camshaft gear is 0.087 ~ 0.211 mm.

NOTE

wheel.
10-180 60068042311 EN - 07/2021 - 01

Diesel engine
NOTE
product.
±0.5 mm thickness.
sembly jig.
NOTE
taching it.
one.
taching it.
dry cloth.
Ø2.5 ±0.5 mm.
NOTE
parts.
tach it.
60068042311 EN - 07/2021 - 01 10-181

Diesel engine
2.2 kgf·m.

idle gear and the 0.087 ~ 0.200 mm
crankshaft gear

en the fixing bolt.

shaft gear

tach it.
of 26 kgf·m.
NOTE

the auto tensioner.
quadrangular tool).
wise.
NOTE

Driving Units”.
10-182 60068042311 EN - 07/2021 - 01

Diesel engine
Measurement of Outside Diameter of Idle
Gear Shaft
 Set the gauge.
 Measure the outside diameter of the idle gear 
shaft.
1) Measure total 4 points of the outside diameter
of the idle gear shaft: vertical (A), horizontal (B),
front (C), and rear (D).
side diameter of the idle gear shaft is within the
range of 59.921 ~ 59.940 mm.

Outside diameter of
59.921 ~ 59.940 mm
the idle gear shaft
Measurement of Inside Diameter of Idle

Gear
 Set the gauge.
 Measure the inside diameter of the idle gear. 
1) Measure total 4 points of the inside diameter

of the idle gear: vertical (A), horizontal (B), front
(C), and rear (D).
side diameter of the idle gear is within the range
of ø60, -0.03 ~ 0 mm.

Inside diameter of the
ø60, -0.03 ~ 0 mm
idle gear
60068042311 EN - 07/2021 - 01 10-183

Diesel engine
Lifting hook
Disassembly of Lifting Hook
 Remove the front lifting hook. 

 Remove the rear lifting hook. 
1) Loosen flange bolt.

10-184 60068042311 EN - 07/2021 - 01

Diesel engine
Assembly of Lifting Hook
 Mount the rear lifting hook. 
1) Mount the rear lifting hook.

que of 4.4 kgf·m.
 Attach the front lifting hook. 

que of 2.2 kgf·m.
60068042311 EN - 07/2021 - 01 10-185

Diesel engine
Electrical system
Electric Parts
1 CAM: CAM Shaft Position Sensor 7 OPS: Oil Pressure Sensor

2 CRK: Crank Shaft Position Sensor 8 RPS: Rail Pressure Sensor
3 WTS: Water Temperature Sensor 9 IMV: Inlet Metering Valve
4 EGT: Exhaust Gas Temperature Sensor 10 INJ: Injector #1
(Stage-V only) 11 INJ: Injector #2
5 EGR: Exhaust Gas Recirculation Valve Posi- 12 INJ: Injector #3
tion Sensor 13 INJ: Injector #4
6 T-MAP Sensor
10-186 60068042311 EN - 07/2021 - 01

Diesel engine
Circuit diagram
General Information
 Circuit diagrams allow you to check the circuit 
number of the connector connected to the en-
gine connector of the engine control unit
(ECU).
 The wire colors are as follows.
1) B: Black
2) Brn: Brown
3) R: Red
4) G: Green
5) W: White
6) L: Blue
7) RG: Red & Green
8) RW: Red & White
9) VL: Violet & Blue
10)O: Orange
11)P: Pink
12)GrL: Gray & Blue
13)RV: Red & Violet
14)RY: Red & Yellow
15)Lgra: Blue & Gray
 The wire types are as follows.
1) FLR91X-A
2) FLR91X-A_T01 (Twist)
9) FLR91X-A_BS01 (Shield)
 ECU PIN No. is the pin number of the engine
connector.
 Sensor PIN No. is the pin number of the sen-
sor connector.
60068042311 EN - 07/2021 - 01 10-187

Diesel engine
Engine Connector
10-188 60068042311 EN - 07/2021 - 01

Diesel engine
Engine Connector of Engine Control Unit (ECU)
Circuit Descrip-
SQ Color Type To From Remarks
No. tion
Rail pres-
FLR91X- sure sen-
A063 0.75 B ECU 63 RPS 1
A_T01 sor
ground
Rail pres-
FLR91X-
A062 0.75 Bm sure sen- ECU 62 RPS 2
A_T01
sor signal
Rail pres-
FLR91X-
A042 0.75 R sure sen- ECU 42 RPS 3
A_T01
sor supply
EGR posi-
A040 0.75 R FLR91X-A tion sen- ECU 40 EGR 1
sor supply
60068042311 EN - 07/2021 - 01 10-189

Diesel engine
FLR91X- EGR mo-

A088 1 G ECU 88 EGR 2
A_T02 tor minus
EGR posi-
tion sen-
A078 0.75 B FLR91X-A ECU 78 EGR 3
sor
ground
EGR posi-
A079 0.75 W FLR91X-A tion sen- ECU 79 EGR 5
sor signal
FLR91X- EGR mo-
A067 1 L ECU 67 EGR 6
A_T02 tor plus
Throttle
position TROT- Stage-V
A016 0.75 R FLR91X-A ECU 16 1
sensor TLE only
supply
Throttle
FLR91X- plate ac- TROT- Stage-V
A009 0.75 LW ECU 9 2
A_T03 tuator mo- TLE only
tor minus
Throttle
plate ac-
TROT- Stage-V
A097 0.75 B FLR91X-A tuator ECU 97 3
TLE only
feedback
ground
Throttle
plate ac-
TROT- Stage-V
A098 0.75 P FLR91X-A tuator ECU 98 5
TLE only
feedback
signal
Throttle
FLR91X- plate ac- TROT- Stage-V
A008 0.75 R ECU 8 6
A_T03 tuator mo- TLE only
tor plus
Coolant
tempera- COOL-
A099 0.75 RG FLR91X-A ture sen- ECU 99 ANT 1
sor TEMP
ground
Coolant
COOL-
tempera-
A100 0.75 RW FLR91X-A ECU 100 ANT 2
ture sen-
TEMP
sor signal
Fuel me-
ME-
FLR91X- tering unit
A007 0.75 VL ECU 7 TERING 1
A_T04 supply
UNIT
(BAT+)
ME-
FLR91X- Fuel me-
A006 0.75 W ECU 6 TERING 2
A_T04 tering unit
UNIT
Crank-
shaft
FLR91X-
A020 0.75 O speed ECU 20 CRANK 1
A_BS01
sensor
signal plus
10-190 60068042311 EN - 07/2021 - 01

Diesel engine
Crank-
shaft
FLR91X- speed
A021 0.75 P ECU 21 CRANK 2
A_BS01 sensor
signal mi-
nus
Crank-
shaft sen-
A057 0.75 B FLR91X-A ECU 57 CRANK 3
sor
ground
Camshaft
speed
A051 0.75 B FLR91X-A ECU 51 CAM 1
sensor
ground
Camshaft
speed
A052 0.75 Bm FLR91X-A ECU 52 CAM 2
sensor
signal
Camshaft
speed
A037 0.75 R FLR91X-A ECU 37 CAM 3
sensor
supply
TMAP
A095 0.75 B FLR91X-A sensor ECU 95 TMAP 1
ground
TMAP
sensor
A061 0.75 G FLR91X-A ECU 61 TMAP 2
signal
(Temp)
TMAP
A038 0.75 R FLR91X-A sensor ECU 38 TMAP 3
supply
TMAP
sensor
A101 0.75 GrL FLR91X-A ECU 101 TMAP 4
signal
(PRES)
Oil pres-
Oil
A014 0.75 R FLR91X-A sure sen- ECU 14 3
PRES
sor supply
Oil pres-
sure sen- Oil
A035 0.75 B FLR91X-A ECU 35 2
sor PRES
ground
Oil pres-
sure sen- Oil
A036 0.75 O FLR91X-A ECU 36 1
sor input PRES
signal
FLR91X- Injector 1 Injec-
A064 1.5 B ECU 64 1
A_T05 "high" tor#1
A085 1.5 RW ECU 85 2
A_T05 "low" tor#1
A024 1.5 RG ECU 24 1
A_T06 "high" tor#2
60068042311 EN - 07/2021 - 01 10-191

Diesel engine

A45 1.5 B ECU 45 2
A_T06 "low" tor#2
A022 1.5 RG ECU 22 1
A_T07 "high" tor#3
A043 1.5 RV ECU 43 2
A_T07 "low" tor#3
A066 1.5 RY ECU 66 1
A_T08 "high" tor#4
A087 1.5 B ECU 87 2
A_T08 "low" tor#4
Exhaust
gas tem-
Stage-V
A033 0.75 O FLR91X-A perature ECU 33 EGT 1
only
sensor
ground
Exhaust
gas tem-
Stage-V
A059 0.75 P FLR91X-A perature ECU 59 EGT 2
only
sensor
signal
Glow plug
A093 0.75 Lgra FLR91X-A ECU 93 Inter 2
relay
Switches and sensors

Injector#1 
A part that injects fuel according to the injection

signal received from the ECU.
No ECU Pin Description

Injector 1
1 64
"High"
Injector 1
2 85
"Low"
10-192 60068042311 EN - 07/2021 - 01

Diesel engine
Injector#2 


Injector 2
1 24
"High"
Injector 2
2 45
"Low"
Injector#3 


Injector 3
1 22
"High"
Injector 3
2 43
"Low"
Injector#4 


Injector 4
1 66
"High"
Injector 4
2 87
"Low"
60068042311 EN - 07/2021 - 01 10-193

Diesel engine
Coolant Temperature Sensor (COOLANT 
TEMP)
A sensor that senses the temperature of engine
cooling water.

Coolant tempera-
1 99
ture sensor ground
Coolant tempera-
2 100
ture sensor signal
Exhaust Gas Recirculation Valve Position 

Sensor (EGR)
A sensor used to reduce nitrogen oxide (NOx)
from the exhaust gas. It recirculates some of the
exhaust gas from the engine to the intake side.
In this way, the combustion temperature is re-
duced and the discharged NOx is reduced.

EGR position sen-
1 40
sor supply
2 88 EGR motor minus
EGR position sen-
3 78
sor ground
EGR position sen-
5 79
sor signal
6 67 EGR motor plus
Crank Shaft Position Sensor (CRANK) 
A sensor that senses the position of the crank-

shaft in order to sense the engine rotation speed
and the position of the piston.

Crankshaft speed
1 20
sensor signal plus
Crankshaft speed
2 21 sensor signal mi-
nus
Crankshaft sensor
3 57
ground
10-194 60068042311 EN - 07/2021 - 01

Diesel engine
CAM Shaft Position Sensor (CAM) 
A sensor that senses the position of the cam-

shaft, allowing it to check the position of each
piston by using the reference points with the
same basis of the crank shaft position sensor
which cannot check the position of each piston.

Camshaft speed
1 51
sensor ground
Camshaft speed
2 52
sensor signal
Camshaft speed
3 37
sensor supply
Temperature Manifold Absolute Pressure 

Sensor (TMAP)
A sensor that measures the pressure and the
temperature of air in the intake manifold.

TMAP sensor
1 95
ground
Camshaft speed
2 61
sensor signal
TMAP sensor sup-
3 38
ply
TMAP sensor sig-
4 101
nal (PRES)
Oil Pressure Sensor (OIL PRES) 
A sensor that measures the pressure of engine

oil in the main gallery.

Oil pressure sen-
1 36
sor input signal
Oil pressure sen-
2 35
sor ground
Oil pressure sen-
3 14
sor supply
60068042311 EN - 07/2021 - 01 10-195

Diesel engine
Rail Pressure Sensor (RPS) 
A sensor that is installed at the end of the com-

mon rail, measuring the instantaneous internal
pressure of the common rail.

Rail pressure sen-
1 63
sor ground
Rail pressure sen-
2 62
sor signal
Rail pressure sen-
3 42
sor supply
Fuel Metering Unit (METERING UNIT) 
A valve mounted on the high-pressure pump. It

adjusts the fuel volume pumped from the pump
to the rail to control the fuel pressure on the rail.

Fuel metering unit
1 7
supply (BAT+)
2 6 Fuel metering unit
Throttle Valve Actuator/Position Sensor 
Throttle Valve measures real value of valve an-

gle for PID control by ECU.

Throttle position
1 16
sensor supply
Throttle plate ac-
2 9
tuator motor minus
Throttle plate ac-
3 97 tuator feedback
ground
Throttle plate ac-
5 98 tuator feedback
signal
Throttle plate ac-
6 8
tuator motor plus
10-196 60068042311 EN - 07/2021 - 01

Diesel engine
Exhaust Gas Temperature Sensor (EGT) 
A sensor that measures the temperature of ex-

haust gas in the exhaust manifold.

Exhaust gas tem-
1 33 perature sensor
ground
Exhaust gas tem-
2 59 perature sensor
signal
Wire harness
Disassembly of Wire Harness Assembly of Wire Harness
1. Disconnect the connectors connected to each 1. Mount the wire harness.
sensor.
2. Tighten the fixing bolts mounted on the wire
2. Loosen the fixing bolts mounted on the wire harness bracket.
harness bracket.
3. Disconnect the connectors connected to each
3. Remove the wire harness. sensor.
Electronic Control Unit (ECU)

General Information
The engine control unit (ECU) controls fuel deliv-
ery.
The ECU is connected to various sensors.
Based on the input values from the sensors, the
ECU controls the engine for optimum operation.
Before disconnecting connectors from the ECU,
disconnect the ground wire (negative (-) wire) of
the battery cable. Do not dismantle the ECU.
60068042311 EN - 07/2021 - 01 10-197

Diesel engine
Electronic Control Unit (ECU) Connectors
1 Connectors connected to the engine 2 Connectors connected to the vehicle
The ECU connectors are classified into the con-

nectors connected to the vehicle and the con-
nectors connected to the engine.
10-198 60068042311 EN - 07/2021 - 01

Diesel engine
I/O of Electronic Control Unit (ECU)
Operational Conditions of Electronic Control

Unit (ECU)
1. Engine Start
1) Sets the reference temperature for determin-
ing preheat to the lowest temperature among
coolant temperature, fuel temperature, intake air
temperature, and oil temperature.
2) Sets the reference temperature for determin-
ing fuel volume by setting the engine cooling
temperature.
3) Determines the appropriate fuel volume to
start the engine, delivers the fuel to the engine,
and measures the RPM signal by using the
crankshaft rev-count sensor.
2. Vehicle driving
60068042311 EN - 07/2021 - 01 10-199

Diesel engine
1) Calculates the required data for driving a ve-
hicle, such as CAN data and the RPM transfer-
red from the vehicle control unit.
3. Driver-requested Adjustment of RPM
1) Controls the RPM based on request from the
driver and controls the engine based on the
RPM requested by the vehicle control unit.
4. Limp Home
1) A function that allows drivers to drive their ve-
hicle to the repair center safely with the mini-
mum conditions for driving the vehicle when a
fault code occurs.
2) Limp Home function is applied under the fol-
lowing conditions.
● Accelerator pedal has failed: Regardless of
pressing the accelerator pedal, the vehicle is
driven at a consistent RPM.
● Sensor has failed: When sensors have failed,
the vehicle is driven with the consistent alter-
native values.
● Output is limited: According to the fault type,
the fuel volume delivered to the engine is limi-
ted. The limit is classified into four levels. The
fuel volume is limited according to the severity
of the fault.
● Diagnosis Information Display Lamp: Pro-
vides information of fault state to drivers for
safe driving.
5. Failure Diagnosis
1) When a fault occurs, the failure diagnosis in-
formation display lamp on the gauge board is
turned on.
2) With the failure diagnosis information display
lamp, drivers can see the fault code.
NOTE
It can be checked from the failure diagnosis in-

formation on the gauge board.
3) It can be diagnosed by connecting the diag-
nosis unit to the check connector at the back of
the driver's seat.
6. Driving record
1) Writes the information related driving to the
ECU.
2) The information on fuel consumption, engine
use time, and ECU use time is written in the
ECU.
3) The information can be monitored with the
ECU diagnosis device.
10-200 60068042311 EN - 07/2021 - 01

Diesel engine
Starter
General Information
The starter is mounted at the rear of the Drive

Plate housing. When disassembling the engine,
put the pinion gear and ring gear of the starter
into fuel, brush them, and then apply grease to
them in order to prevent rust.
60068042311 EN - 07/2021 - 01 10-201

Diesel engine
Wiring Diagram 
NOTE
The starter should be away from moisture in any

case and any time.
NOTE
Before working on the electrical system, sepa-

rate the ground wire (negative (-) wire) of the
battery. Short circuit may occur while working on
the electrical system. Connect the ground wire
last after completing all of work.
Disassembly of Starter

10-202 60068042311 EN - 07/2021 - 01

Diesel engine
Assembly of Starter

4.4 kgf·m.
Alternator
General Information 
The alternator is fitted with integral silicon rectifi-

ers.
A transistorized regulator mounted on the alter-
nator body interior limits the alternator voltage.
The alternator should not be operated except
with the regulator and battery connected in cir-
cuit to avoid damage to the rectifier and regula-
tor.
60068042311 EN - 07/2021 - 01 10-203

Diesel engine
Wiring Diagram 
The alternator is maintenance-free, neverthe-

less, it must be protected against dust and,
above all, against moisture and water.
Disassembly of Alternator

quadrangular tool).
 Detach the alternator. 
1) Loosen bolts and remove the alternator.

2) When loosing bolt, take care not to lose nut.
10-204 60068042311 EN - 07/2021 - 01

Diesel engine
Assembly of Alternator
1) Using bolt B and nut, attach the alternator

temporarily.
nator properly.
3) Tighten bolts to a torque of 4.4 kgf·m.

the auto tensioner.
quadrangular tool).
wise.
NOTE

Driving Units”.
Other/drive system
General information
General information
1. The forged crankshaft is an integral structure.
The crankshaft and the rear oil seals prevent oil
from permeating into the Drive Plate housing.
2. The connecting rod is forged and its large end
part is vertically separated.
Therefore, like a piston, the connecting rod can
be disassembled through the upper side of the
cylinder.
60068042311 EN - 07/2021 - 01 10-205

Diesel engine
An alloy-type prefabricated bearing is used for
the active part of the crankshaft and the con-
necting rod.
3. The camshaft, oil pump, and high-pressure in-
jection pump are driven by gear connection in
the timing gear case.
Specifications
Specifications
Item Remarks
DM02-MFF05
Others/Driving System
Grade A: 89.920 ~
Piston outside diameter 89.930 mm Grade B:
89.930 ~ 89.940 mm
Gap between cylinder and piston 0.060 ~ 0.080 mm
Top ring groove 1.915 ~ 1.945 mm
Piston ring groove area 2nd ring groove 2.060 ~ 2.080 mm
Oil ring groove 3.020 ~ 3.040 mm
Top ring side gap 0.083 ~ 0.133 mm
Piston ring side gap 2dn ring side gap 0.070 ~ 0.110 mm
Oil ring side gap 0.030 ~ 0.070 mm
Top ring end gap 0.20 ~ 0.30 mm
Piston ring end gap 2nd ring end gap 0.55 ~ 0.70 mm
Oil ring end gap 0.2 ~ 0.4 mm
Piston pin outside diameter 30.995 ~ 31,000 mm
Piston pin hole bore 31.008 ~ 31.014 mm
Piston pin hole gap 0.008 ~ 0.019 mm
Connecting rod small-end bore 31.025 ~ 31.038 mm
Connecting rod small-end hole gap 0.025 ~ 0.043 mm
Connecting rod large-end bore 57,000 ~ 57.015 mm
Connecting rod bearing oil gap 0.026 ~ 0.064 mm
Connecting rod end play 0.15 ~ 0.3 mm
Crankshaft main journal outside diameter 57.955 ~ 57.970 mm
Crankshaft pin journal outside diameter 53.955 ~ 53.970 mm
Crankshaft main bearing oil gap 0.029 ~ 0.059 mm
Crankshaft end play 0.1 ~ 0.31 mm
Crankshaft
Disassembly of Crankshaft
1. Remove the crankshaft.
NOTE

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Diesel engine
Assembly of Crankshaft
1. Attach the crankshaft.
NOTE

bling an Engine”.
Measurement of Crankshaft Main Journal

Diameter
 Check whether there is any cracked or
scratched part on the journal and pins of the
crankshaft with the naked eye.
 Perform the magnetic particle testing or the
liquid penetrant testing to check the cracks on
the crankshaft. If cracks are found, replace
the crankshaft with a new one.
 Set the gauge.
 Remove foreign substances from the crank-
shaft.
 Measure the diameter of the crankshaft main 
journal.
1) Measure the diameter of the crankshaft jour-
nal with the outside diameter micrometer.
of the idle gear: 5 points of vertical (A), horizon-
tal (B), front (C), and rear (D).
3) The standard measurement value of the di-
ameter of the crankshaft journal is within the
range of 57.955 ~ 57.970 mm.

Crankshaft journal di-
57.955 ~ 57.970 mm
ameter
Measurement of Crankshaft Bearing Gap

 Mount the crankshaft to the cylinder block.
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Diesel engine
 Measure the gap of the crankshaft bearing. 
1) Put the plastic gauges on 5 points on the

crankshaft which contact with the crankshaft
bearing part.
2) Assemble the crank case at the specified tor-
que and then disassemble it.
3) Check the width of the plastic gauges.
4) The standard measurement value of the gap
of the crankshaft bearing is within the range of
0.029 ~ 0.059 mm.

Crankshaft Bearing
0.029 ~ 0.059 mm
Gap
 Remove the plastic gauges.

 Remove any foreign substances from the cyl-
inder block and the crankshaft.
Measurement of Crankshaft Warpage

 Measure the crankshaft warpage. 
1) Put the #1 and #5 main journal of the crank-

shaft on the V- block.
2) Put the dial gauge on the surface plate and
measure the warpage of the crankshaft as spin-
ning the crankshaft.
3) The standard measurement value of the war-
page of the crankshaft is 0.02 mm for #2 and #4
and 0.03 mm for #3 based on #1 and #5 main
journal.
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Diesel engine
Disassembly of Timing Wheel

quadrangular tool).

NOTE

auto tensioner.
speed sensor.
NOTE

ones.
60068042311 EN - 07/2021 - 01 10-209

Diesel engine
Assembly of Timing Wheel


NOTE

wheel.
NOTE
product.
±0.5 mm thickness.
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Diesel engine
 

sembly jig.
NOTE
taching it.
one.
taching it.
dry cloth.
Ø2.5 ±0.5 mm.
NOTE
parts.
tach it.
2.2 kgf·m.
en the fixing bolt.
60068042311 EN - 07/2021 - 01 10-211

Diesel engine

tach it.
of 26 kgf·m.
NOTE

the auto tensioner.
quadrangular tool).
wise.
NOTE

Driving Units”.
Piston
Disassembly of Piston
1. Detach the piston.
NOTE

Assembly of Piston
1. Attach the piston.
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Diesel engine
NOTE

bling an Engine”.
Measurement of Outside Diameter of Piston

Pin
 Set the gauge.
 Measure the outside diameter of the piston 
pin.
1) Measure total 8 points of the piston pin out-
side diameter: A, B, C, and D, in the vertical (E)
and horizontal (F) directions.
2) Measure all 4 points of the piston pin.
side diameter of the piston pin is within the
range of 30.995 ~ 31 mm.

Piston pin outside di-
30.995 ~ 31 mm
ameter
Measurement of Inside Diameter of Piston

Pin Bore
 Set the gauge.
 Measure the inside diameter of the piston pin 
bore.
of the piston pin bore: A, B, C, D, vertical (E),
and horizontal (F).
2) Measure all of 4 piston pin bores.
side diameter of the piston pin bore is within the
range of 31.008 ~ 31.014 mm.

Piston pin of the piston
31.008 ~ 31.014 mm
Inside diameter of bore
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Diesel engine
Measurement of Gap of Piston Ring End
 Measure the gap of the piston ring end. 
1) Insert the piston ring to the cylinder top at a

right angle with the wall.
2) Measure the piston ring end gap with the gap
gauge (A).
3) Measure the gaps of the top ring, the 2nd
ring, and the oil ring.
4) The standard measurement values of the gap
of the piston ring end is within the range of 0.20
~ 0.35 mm for the top ring, 0.55 ~ 0.70 mm for
the 2nd ring, and 0.20 ~ 0.40 mm for the oil ring.

Gap of top ring 0.20 ~ 0.35 mm
Gap of 2nd ring 0.55 ~ 0.70 mm
Gap of oil ring 0.20 ~ 0.40 mm
NOTE
Be careful not to damage the cylinder with the

gap gauge when measuring the gap of the pis-
ton ring end.
Measurement of Step Height of Piston Top

Side
 Perform the zero point adjustment of the me-
ter based on the top surface of the cylinder
block.
 Measure the step height of the piston top 
side.
1) Adjust the piston to position on the top dead
point.
2) Measure the step height on A and B on the
piston top side based on the cylinder block sur-
face.
3) Adjust the other pistons to position on the top
dead point and measure 8 points.
4) The standard measurement value of the step
height of the piston top side is within the range
of 0.11 ~ 0.39 mm.

Step height of piston
0.11 ~ 0.39 mm
top side
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Diesel engine
NOTE
● Select the cylinder head gasket class based
on the average of step heights of the piston
top side by measuring average value of step
heights at 8 points. For the cylinder gasket
class, refer to #19 of Procedure of Assem-
bling an Engine of General Information.
● The front engine direction (F) is the water
pump direction and the rear engine direction
(R) is the Drive Plate direction.
Connecting rod
Disconnection of Connecting Rod
1. Disconnect the connecting rod.
NOTE

sembling an Engine“.
Assembly of Connecting Rod

1. Connect the connecting rods.
NOTE
Refer to Chapter entitled ”Procedure of Assem-

bling an Engine“.
Measurement of Inside Diameter of Con-

necting Rod Small-end
 Set the gauge.
 Measure the inside diameter of the small end 
of the connecting rod.
of the connecting rod small-end: vertical (A),
horizontal (B), front (C), and rear (D).
2) Measure all of 4 connecting rods.
side diameter of the connecting rod small-end is
within the range of 31.025 ~ 31.038 mm.

Connecting rod small-
31.025 ~ 31.038 mm
end bore
Measurement of Connecting Rod Large-end

Bore
 Set the meter.
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Diesel engine
 Measure the inside diameter of the large-end 
of the connecting rod.
of the connecting rod big-end: A, B, C, front (D),
and rear (E).
2) Measure all of 4 connecting rods.
side diameter of the connecting rod big-end is
within the range of 57.0 ~ 57.015 mm.

Connecting rod large-
57.0 ~ 57.015 mm
end bore
NOTE
Connect the connecting rods manually until the

head of the connecting rod bolt contacts the bolt
bearing surfaces on both sides, and then tighten
them at the specified torque.
Measurement of Gap of Connecting Rod

Big-end
 Mount the crankshaft to the cylinder block.
 Measure the gap of the connecting rod big- 
end.
1) Put the plastic gauges on 4 points on the
crankshaft that contacts with the connecting
rods.
2) Connect the connecting rods.
3) Temporarily connect the connecting rods
manually.
4) Tighten the connecting rod bolts at a tighten-
ing torque of 2 kgf m + 90 with the angle meth-
od.
5) Loosen the connecting rod bolts.
6) Remove the connecting rod cap.
7) Check the width of the plastic gauges.
8) The standard measurement value of the gap
of the connecting rod big-end is within the range
of 0.026 ~ 0.064 mm.

Gap of Connecting
0.026 ~ 0.064 mm
Rod Big-end
 Remove the plastic gauges.

1) Remove the plastic gauges.
2) Remove any foreign substances from the
crankshaft and the connecting rod big-end.
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Diesel engine
Flywheel
Disassembly of Flywheel


60068042311 EN - 07/2021 - 01 10-217

Diesel engine
Assembly of Flywheel

torque.

option) ±4°
wheel
NOTE


4.4 kgf·m.
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Diesel engine
Crankshaft pulley
Disassembly of Crankshaft Pulley

quadrangular tool).

NOTE
60068042311 EN - 07/2021 - 01 10-219

Diesel engine
Assembly of Crankshaft Pulley

tach it.
of 26 kgf·m.
NOTE

the auto tensioner.
quadrangular tool).
wise.
NOTE

fer to Belt Tension in Chapter entitled ”Others/
Driving Units“.
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Diesel engine
Others
Engine Timing 
The camshaft, oil pump, and high-pressure in-

jection pump are driven by gear connection.
Adjustment of Engine Timing

 Remove the timing gear case.
1 Idle gear (gear: 65)

2 Camshaft gear (gear: 60)
3 Crankshaft gear (gear: 30)
4 Oil pump drive gear (gear: 25)
5 Injection pump gear (gear: 30)
6 PTO gear (gear: 30)
 Align the engravings of gears. 

(D) between the idle gear engravings (A).
NOTE
● You can see one crankshaft gear engraving
(F) and two idle gear engravings (E).
● Position the idle gear engraving (A) between
the camshaft gear engravings (B).
● You can see one idle gear engraving (H) and
two camshaft gear engravings (G).
 Mount the timing gear case.
Check of Gear Backlash

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Diesel engine
 Check the gear backlash. 
1) Check the gear backlash with the gap gauge.

2) The standard backlash between the idle gear
(A) and the crankshaft gear is 0.087 ~ 0.2 mm.
3) The standard backlash between the oil pump
drive gear and the crankshaft gear (B) is 0.06 ~
0.259 mm.
4) The standard backlash between the idle gear
and the camshaft gear (C) is 0.067 ~ 0.211 mm.

the idle gear
crankshaft gear and oil 0.06 ~ 0.259 mm
pump drive gear
shaft gear
Check of Gear Axial Offset

 Check the gear axial offset. 
1) Mount the dial gauge on the cylinder block.

2) Press the crankshaft gear (A) into the cylinder
block direction.
3) Perform the zero point adjustment of the dial
gauge based on the crankshaft gear (A).
4) Pull the crankshaft gear (A) and check the
measured value of the dial gauge.
NOTE
The axial offset of the crankshaft gear is 0.100 ~

0.300 mm.
5) Press the camshaft gear (B) into the cylinder
block direction.
gauge based on the camshaft gear (B).
7) Pull the camshaft gear (B) and check the
measured value of the dial gauge.
NOTE
The axial offset of the camshaft gear is 0.1 ~ 0.2

mm.
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Diesel engine
8) Press the idle gear (C) into the cylinder block
direction.
gauge based on the idle gear (C).
10)Pull the idle gear (C) and manually measured
value of the dial gauge.

The axial offset of the
0.100 ~ 0.300 mm
crankshaft gear
0.1 ~ 0.2 mm
camshaft gear
0.1 ~ 0.2 mm
idle gear
NOTE
The axial offset of the idle gear is 0.1 ~ 0.2 mm.

Description of diagnostic software

Description of diagnostic software
 Open the software 
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Diesel engine
 Enter the account number and password 
 Select "Diagnosis" mode 
 Click "Start" to enter menu 
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Diesel engine
 Enter the "Fault Codes" menu 
 Select the error number 
 View specific information 
60068042311 EN - 07/2021 - 01 10-225

Diesel engine
 Compare parameter details 
 View fault explanation 
NOTE
Please refer to the engine fault diagnosis man-

ual for the corresponding fault explanation.
 Enter data monitoring, view real-time data 
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Diesel engine
 Select the data that you want to view and 
click to start recording (recording needs to
collect three statuses: idle speed, medium
speed and high speed; data needs to be col-
lected for at least two minutes for each state)
 Once the data collection has finished, the da- 

ta can be saved in a folder for comparison
and viewing
 Click on the historical data to view 
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Diesel engine
 Enter the "Snapshot Viewer" to record and 
view real-time engine data
 Enter the "Engine Test" to test the engine 

based on the fault symptoms
 Shut Off Test: A cylinder shut-off test can be 

performed on the engine. The resulting data
can be collected and viewed
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Diesel engine
 Compression Test: Testing can be performed 
in the engine to test the pressure of each cyl-
inder
 Glow Plug Test: Checks glow plugs based on 

a change in voltage
 Engine Speed: Checks whether the current 

engine speed corresponds to the setpoint
60068042311 EN - 07/2021 - 01 10-229

Diesel engine
 SCR Leak Test: Used to check whether the 
after-treatment fluid is leaking
 SCR Emptying Test 
 SCR Complete Test: Used to check whether 

the pressurisation, dosing, injection and emp-
tying levels in the SCR system are normal
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Diesel engine
 Long Storage Action: Tests the operation of 
the engine following long-term storage
 Metering Unit Test: Record and view oil pump 

data
 Rail Pressure Test: Record the required rail 

pressure and set the rail pressure
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Diesel engine
 Input/Output Test: Record and view ECU in- 
put/output signals
 After-treatment error detection 
 Confirm replacement of parts 
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Diesel engine
 Reprogramming: Select the update from the 
folder and reprogram
 ECU Information 
 Summary: Information regarding the main 

units
60068042311 EN - 07/2021 - 01 10-233

Fuel system
Fuel system
The fuel system is principally composed of the

fuel tank, fuel tank cap, fuel filter and fuel line.
NOTE
● When installing the fuel tank cap, the interior
of the fuel tank must be clean;
● When installing the fuel tank cap, you should
check that the filter and steel pipe are intact;
● When connecting the line, you must ensure
that the connection point is intact;
● After installation is complete, you must bleed
air from the low pressure fuel system.
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Cooling system engine

Radiator 
The radiator is an accessory used to effectively

reduce the temperature of the engine and hy-
draulic transmission.
Precautions for radiator installation:
1. To avoid damaging the radiator, be careful not
to bump it during installation;
2. When installing, make sure that one-third of
the fan is inside the fan shroud;
3. When installing, make sure to maintain an ap-
propriate distance between the top, bottom, left
and right of the fan and the fan shroud
60068042311 EN - 07/2021 - 01 10-235

Particle filter
Exhaust pipe and gas exhaust aftertreatment device installation
The exhaust pipe and gas exhaust aftertreat-

ment device are components that vent exhaust
emissions and lower environmental pollution.
CAUTION
When installing the exhaust pipe and gas exhaust af-
tertreatment device, pay attention to the positioning of
the exhaust pipe and the muffler to prevent the ex-
haust pipe hose from twisting.
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Particle filter
General description 
Doosan Infracore engines use DOC (diesel oxi-

dation catalysts) and DPF (diesel particulate fil-
ters) to meet the 5-stage legal requirements for
venting exhaust. DOC is an oxidation catalyst
that uses catalysts to reduce HC and CO emis-
sions. DPF collects particulate matter (PM) re-
leased by the diesel engine.
Quan
No. Part name
tity
DOC (diesel oxidation cata-
1 1
lyst)
DPF (diesel particulate fil-
2 1
ter)
3 Temperature sensor 1
4 DPF Delta P sensor 1
A Diesel engine
B Engine disposal
Aftertreatment muffler C ECU
D Actuator
The aftertreatment muffler is composed of the E Sensor
F Engine CAN
DOC and DPF mufflers. That is to say, the after-
G Diagnostic CAN
treatment muffler combines both the DOC (die-
sel oxidation catalyst) and DPF (diesel particu-
late filter) mufflers.
Diesel oxidation catalyst (DOC)

Overview:
A DOC (diesel oxidation catalyst) is a system
that vents oxidation and reduces HC (hydrocar-
bon) and CO (carbon monoxide). H2O (water)
and CO2 (carbon dioxide) are generated in the
process. Active regeneration mode raises DPF
temperature to assist with oxidation, venting HC
(hydrocarbon) through the exhaust pipe. It also
speeds up passive regeneration of particulate
matter (PM) being gathered by converting NO
(nitric oxide) into NO2 (nitrogen dioxide). As
shown in the image below, the temperature sen-
sor is installed in front of the DPF (diesel particu- 1 DOC
late filter) in order to control DOC temperature 2 Temperature sensor
between active regeneration periods. 3 DPF
4 DPF delta P sensor
60068042311 EN - 07/2021 - 01 10-237

Particle filter
Diesel particulate filter (DPF) 
Overview:
The DPF (diesel particulate filter) system is used
to prevent particulate matter (PM) within the ex-
haust from being emitted into the air. The sys-
tem is composed of the DPF body, exhaust gas
temperature sensor and a pressure differential
sensor. The DPF has a porous wall that can fil-
ter out particulate matter. When exhaust gas
passes through the DPF, particulate matter ac-
cumulates in the DPF and the remaining ex-
haust gas passes from the DPF into the SCR
system. Afterwards, a suitable regeneration
method removes the PM accumulated in the
DPF.
DPF regeneration:
The DPF is used to filter out pollutant soot that
accumulates in diesel exhaust matter. Too much
soot accumulating in the DPF can cause prob-
lems, such as reduced engine power due to in-
creased back pressure on the engine. There-
fore, it is very important to carry out regeneration
to remove PM from the DPF. The ECU (engine
control unit) is used to calculate the amount of
exhaust based on the DPF differential sensor
signal, the vehicle's operating hours, the vehi-
cle's fuel consumption, and the engine's simula-
ted data. Once the amount reaches a certain
level, the ECU will set the DPF to regenerate.
Regeneration — a process which involves burn-
ing accumulated PM — increases the tempera-
ture upstream of the DOC by means of adjust-
ment of the engine throttle and near post injec-
tion, as well as raising the DPF temperature
higher than the exhaust combustion temperature
(580° or higher) to burn exhaust gas by means
of far post injection. Following DPF regenera-
tion, only residual cinders will be left in the DPF.
DPF regeneration includes forced regeneration
that occurs while driving (active regeneration)
and forced regeneration that the driver activates
(manual regeneration) (forced regeneration).
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Running gear and drive train 20
Torque converter
Hydraulic transmission gearbox
The hydraulic transmission gearbox consists of
four components: a torque converter, an electro-
hydraulic shift gearbox with one forward and one
reverse gear, a retarder, and a differential. The
torque converter installed on the gearbox is a
single-stage, two-phase, three-wheel integrated
hydraulic torque converter. The hydraulic trans-
mission gearbox outputs power to the differential
side gears. The shifting method used by the
gearbox is an electro-hydraulically controlled
shift, with an inching valve and buffer valve that
enable simple, convenient operation and smooth
starting, and greatly reduce operator effort.
Main technical parameters

Item YQXD30LDP2-3 YQX30MS1
Engine power rating kW 33–40 33–40
Rated revolutions of engine r/min 2250–2650 2250–2650
Transmission ratio 18.947 17.4972
Main oil pressure MPa 18.947 17.4972
Main oil pressure MPa 1.1–1.4 1.1–1.4
Torque converter inlet pressure
0.5–0.7 0.5–0.7
MPa
Model no. YJH265ⅡD-2 YJH265
Effective diameter mm 265 265
Torque ratio under zero
K0≥3 3±0.15
Hy- working state
draulic Maximum efficiency ≥0.8 ＞ 0.79
torque Nominal torque of impeller
con- under zero working 31.83±1.67 33.5±1.7
verter state N⋅m
Nominal torque of impeller
under max. efficiency 28.5±1.5 31±1.6
working state N⋅m
Steering direction (facing input
Clockwise Clockwise
shaft)
6# or 8# hydraulic transmission 6# or 8# hydraulic transmission
Working fluid
oil oil
Working oil temperature °C 70–95 70–95
Max. working oil temperature °C 120 (no more than 5 min) 120 (no more than 5 min)
Overall dimensions (LxWxH in mm) 830×470×450 851×470×450
Net weight kg 185±1 180
60068042311 EN - 07/2021 - 01 20-1

Torque converter
Structure
Structure
1 Gear shaft 10 Output shaft

2 Tapered roller bearing 11 Idler
3 Torque converter housing components 12 Output gear
4 Feed pump assembly 13 Hydraulic torque converter
5 Electrohydraulic control valve assembly 14 Inching valve assembly
6 Clutch assembly 15 Differential assembly
7 Support plate 16 Spiral bevel gear
8 Housing 17 Bearing cap
9 Idler spindle
The hydraulic transmission gearbox consists of cludes a clutch assembly (6), idler (11), output
four parts: a torque converter(13), gearbox, re- gear (12), idler shaft (9), electrohydraulic control
tarder and differential. Power output from the en- valve assembly (5), inching valve assembly (14)
gine is subjected to torque conversion in the tor- and feed pump assembly (4), and other main
que converter, where it is input via the splined parts and components. The retarder principally
coupling of the turbine shaft to the clutch assem- consists of an output shaft (10), a spiral bevel
bly(6) of the transmission gear. The gearbox in- gear (16), a gear shaft (1) and other
20-2 60068042311 EN - 07/2021 - 01

Torque converter
components. The gear shaft is supported at sembly (15), generating a differential drive which
each end by tapered roller bearings (2). Both is supplied to the wheels via the half-axle gears
ends are fitted with adjuster shims, which are and half-axles. Part (8) is the gearbox housing,
used to adjust the bevel gear colour marking, which houses the gears, shift clutch, reduction
backlash and bearing clearance. The power gear and differential, and can also be used for
from the transmission gear is decelerated by the storing transmission oil.
retarder and transmitted to the differential as-
Hydraulic torque converter
1 Turbine shaft 4 Turbine

2 Impeller 5 Flex plate
3 Stator 6 Double-end bearing
The torque converter mainly consists of a tur- enhance the wear resistance of the torque con-
bine shaft (1), impeller (2), stator (3), turbine (4), verter.
flex plate (5) and other elements. The difference
The impeller (2) is connected by means of a flex
compared with YJH265 lies in the use of double-
plate (5) to the engine flywheel. The impeller
end bearings instead of a wear-resistant liner, to
converts the mechanical energy of the engine
60068042311 EN - 07/2021 - 01 20-3

Torque converter
into the kinetic energy of the working fluid, and and stator. Therefore, the output torque is great-
forces the fluid along the impeller vanes at high er than the input torque, resulting in automatic
speed into the turbine (4), causing it to rotate. torque multiplication. When the turbine-impeller
The fluid is output from the turbine shaft (1), speed ratio exceeds a given value, the stator
transferring torque and rotational speed to the freewheels and torque multiplication ceases.
gearbox. After leaving the turbine, the fluid flows This is called the coupling phase.
into the stator (3). During the torque multiplica-
tion phase, under high load and at low turbine
speed, the stator is prevented from rotating by NOTE
the one-way clutch and thus redirects torque ex-
Stamp-welded torque converter — cannot be
erted by fluid flow against the impeller back to- disassembled.
wards the turbine, so that the torque on the tur-
bine is equal to the sum of that on the impeller
Feed pump assembly
1 Drive gear 2 Stator base
20-4 60068042311 EN - 07/2021 - 01

Torque converter
3 Passive gear 4 Pump housing
The feed pump assembly principally consists of

a drive gear (1), a stator base (2), a passive
gear (3), pump housing (4) and other parts. The
feed pump assembly is mounted on the torque
converter housing. The stator base (2) is spline-
coupled to the stator. The pump housing (4) is
cast with a high-pressure chamber and a low-
pressure chamber. The driving gear (1) con-
nects to the impeller and, driven by the engine,
turns the passive gear (3), forming an internal
gear pump that supplies the system with oil.
Inching valve assembly
1 Inching valve body 3 Return spring

2 Dual-slot plug
60068042311 EN - 07/2021 - 01 20-5

Torque converter
4 Inching valve stem
The inching valve assembly principally consists clutch pressure starts to decrease; when the
of an inching slider body (1), dual-slot plug (2), clutch pressure decreases to a certain level, the
return spring (3), inching valve stem (4) and oth- friction disc slips, thereby enabling the vehicle to
er parts. The inching valve assembly is mounted inch. When the inching valve stem moves out-
on the outside of the gearbox. The inching valve ward by 10 mm, the clutch pressure decreases
stem is connected to the inching pedal connect- to 0, the clutch friction disc and spacer cannot
ing rod. The inching valve stem moves outward engage, and the vehicle stops moving. When
when the inching pedal is depressed. When the the inching valve stem moves outward by
inching valve stem moves outward by 2 mm, the 29 mm, it reaches the end of its stroke.
Clutch assembly
1 Input shaft 7 Friction plate

2 Forward gear wheel 8 Spacer plate
3 O-ring 9 Return spring
4 Piston 10 Reverse gear wheel
5 Clutch housing 11 Seal ring
6 Seal ring 12 Bearing
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Torque converter
13 Snap ring
The clutch assembly consists of an input shaft ted with a seal ring (6), and an O-ring (3) on the
(1), forward gear wheel (2), piston (4), clutch input shaft ensures proper sealing during clutch
housing (5), friction plate (7), spacer plate (8), operation. When the direction lever is in neutral,
return spring (9), reverse gear wheel (10), seal unpressurised oil enters the clutch and the pis-
ring (11) and other parts and components. The ton is reset by the spring force of the return
left and right clutches are wet multi-plate hy- spring, so that the spacer plates and friction
draulic clutches, each equipped with four plates are separated. When the gear is shifted,
spacers and four friction plates mounted alter- hydraulic pressure acts on the piston so that the
nately. The clutch housing and input shaft are spacer plates and friction plates bond together,
welded together. Pressurised oil flows through relying on friction to transmit power from the tor-
the control valve and is distributed into the for- que converter to the forward or reverse gear
ward or reverse clutch to achieve forward or re- wheel.
verse shifting. The outer circle of the piston is fit-
60068042311 EN - 07/2021 - 01 20-7

Torque converter
Differential assembly
1 Thrust washer 8 LH differential casing

2 Gear (1) 9 Bearing
3 Gear (2) 10 Differential side gear
4 RH differential casing 11 Planetary gear
5 Bolt 12 Washer
6 Ring gear 13 Parallel pin
7 Bolt
The differential assembly is supported on the

gearbox housing at both ends by ball bearings
(9). The differential assembly is equipped with
two differential side gears (10) and four planeta-
ry gears (11). The planetary gears are supported
by gear shaft (2) and gear shaft (3). Gear shaft
(3) is fixed by means of a parallel pin (13) onto
the right-hand differential casing (4). A thrust
washer (1) and washer (12) are installed be-
tween the differential casing and the planetary
gears/differential side gears. The differential
20-8 60068042311 EN - 07/2021 - 01

Torque converter
casing is split into left and right parts. The left-
hand differential casing (8) and right-hand differ-
ential casing (4) are connected by means of bolt
(7). The ring gear (6) is secured by bolt (5) onto
the right-hand differential casing.
Electrohydraulic control valve 
The electrohydraulic control valve consists of

parts such as the housing cover, solenoid switch
valve, and control valve assembly. The control
valve assembly is located on the inside of the
housing cover, which is equipped with a torque
converter inlet relief valve. The control valve as-
sembly contains a main pressure valve and two
buffer valves. The main pressure valve controls
oil pressure on the clutch to be within a range of
1.1 Mpa and 1.4 Mpa. Some of the oil goes
through an inching valve into the actuation valve
to change gears, while other oil goes into the
pressure relief valve to adjust the oil pressure to
be within a range of 0.5 Mpa and 0.7 Mpa, and
then into the torque converter. The buffer valves
are used to reduce the impact of clutch engage-
ment and disengagement. 1 Housing cover
2 Solenoid valve
3 Control valve assembly
1 Main pressure valve

2 Buffer valve
3 Operating valve
60068042311 EN - 07/2021 - 01 20-9

Torque converter
Working principle
Transmission principle of gearbox
1 Flex plate 12 Gear shaft

2 Turbine 13 Ring gear
3 Stator 14 Differential side gear
4 Impeller 15 Differential assembly
5 Turbine shaft 16 Planetary gear
6 Oil pump 17 Spiral bevel gear
7 Forward gear wheel 18 Idler spindle
8 Friction plate 19 Idler
9 Spacer plate 20 Output shaft
10 Reverse gear wheel 21 Output gear
11 Input shaft assembly
The schematic diagram of the hydraulic trans- impeller vanes at high speed into a turbine 2,
mission gearbox is shown in Figure 1. The hy- causing it to rotate. The impeller 3 is what ena-
draulic torque converter is connected to the en- bles the torque converter to achieve a torque
gine by way of a flex plate 1. The flex plate multiplication effect. The torque is transmitted
drives an impeller, which forces fluid along the
20-10 60068042311 EN - 07/2021 - 01

Torque converter
via the turbine shaft 5 to the input shaft assem- 13, which drives the differential 15 output. The
bly 11 of the hydraulic transmission gearbox. forward and reverse clutches are controlled by
When the forward gear is engaged, the reverse the shift operating valve. The oil pump 6 is an in-
clutch idles, and the transmission sequence is ternal gear pump and is driven directly by the
part 11 → part 7 → part 21 → part 20 → part 17 → engine via the pump impeller. The oil pump sup-
part 12 → part 13, which drives the differential 15 plies oil under pressure to the system. After be-
output. When the reverse gear is engaged, the ing used by the torque converter, the oil flows in-
forward clutch idles, and the transmission se- to the vehicle's radiator and then into the gear-
quence is part 11 → part 10 → part 18 → part 19 box, where it lubricates the friction plates, bear-
→ part 21 → part 20 → part 17 → part 12 → part ings and gears.
Power flow
60068042311 EN - 07/2021 - 01 20-11

Torque converter
Oil line schematic
20-12 60068042311 EN - 07/2021 - 01

Torque converter
60068042311 EN - 07/2021 - 01 20-13

Torque converter
Oil line schematic for the hydraulic transmission

gearbox. In the figure, F indicates forward gear,
R indicates reverse gear, and N indicates neu-
tral gear.
20-14 60068042311 EN - 07/2021 - 01

Torque converter
Gearbox disassembly procedure and precautions (same for manual and

electronic versions)
Drain the oil
 Unscrew the oil drain bolt (1) at the position 
shown in the figure to drain the oil in the gear-
box.
 After draining the oil, screw the drain bolt (1)
back onto the gearbox.
Tightening torque of oil drain bolt (1): 60-80 N
m
Remove the differential assembly 
 Knock out the locking plate on the bearing

support, unscrew the bolt (1).
 Remove the bearing support (2).
 After removing the differential assembly (3),
re-install the bearing support (2) on the gear-
box case.
Tightening torque of differential bearing support
bolts (1): 200-230 N m
NOTE
Mark the bearing support before removing it, to

prevent misalignment.
60068042311 EN - 07/2021 - 01 20-15

Torque converter
Remove the torque converter assembly 
 Take out the torque converter assembly (1).
Removing the oil pump assembly 
 Remove the oil pump bolt (1), then take out

the oil pump assembly (2).
Tightening torque of oil pump bolt (1): 20-25 N
m
Remove the torque converter housing, 3 

O-rings and paper gaskets
 Remove the torque converter housing con-
nection bolt (1)
 Remove the torque converter housing (2),
and remove the O-rings (3) (4).
Tightening torque of torque converter housing

bolt (1): 40-50 N m
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Torque converter
Remove the control valve assembly, 2 

O-rings and paper gaskets
 Remove the control valve retaining bolt (1),
control valve assembly (2) and O-rings (3).
Tightening torque of control valve bolt (1):
45-55 N m
Remove the inching valve assembly and 

paper gasket
 Remove the inching valve bolt (1), then re-
move the inching valve assembly (2)
Tightening torque of inching valve bolt (1):
25-32 N m
Remove the oil filter assembly, paper

gasket and dipstick
 Take out the dipstick (1)
 Remove the oil filter cover plate bolt (2)
60068042311 EN - 07/2021 - 01 20-17

Torque converter
 Remove the oil filter assembly (3) 
Tightening torque of filter insert clamping plate

(2): 45-55 N m
Remove the clutch assembly and idler

shaft assembly
 Take out clutch assembly (1) and idler gear 
assembly (2).
20-18 60068042311 EN - 07/2021 - 01

Torque converter
Remove the bearing caps and adjust- 

ment shims at both ends
 Remove the cover plate bolt (1), remove the
cover plate (2) (note the thickness of the left
and right adjustment shims (3))；
 Tap the gear shaft near one end of the bevel
gear (4);
 Remove the gear shaft (5), the bearings at
both ends(6), the bushing (7) and bevel gear
(4).
Tightening torque of small splined shaft clamp-

ing plate bolt (1): 40-50 N m
NOTE
Apply marks to avoid mixing up the adjustment

gaskets on the left and right of the bearing cov-
er. When reassembling the gearbox, install them
in the previous position, in the same direction
and quantity.
Remove the support piece and output 

shaft assembly
 Remove the support piece bolt (1), support
piece (2), gasket (3) and spacer (4);
 Strike the front end of the output shaft assem-
bly (5) with a rubber mallet to extract the out-
put shaft assembly (5) and spacer (6).
Tightening torque of output shaft clamping plate
bolt (1): 20-25 N m
NOTE
The adjustment shims under the support piece

must be reinstalled in the original quantities dur-
ing assembly. The output shaft adjustment
shims at the rear must all be replaced in their
original positions during assembly.
60068042311 EN - 07/2021 - 01 20-19

Torque converter
Remove the output gear and idler gear 

from the torque converter housing
 Extract the output gear (1) and idler gear (2)
on the torque converter housing.
NOTE
2 gear positions.
Disassemble the differential assembly 

and ring gear
 Pry off the differential ring gear safety piece
(1), remove the differential ring gear retaining
bolt (2) and nut (3);
 Remove the differential ring gear (4); pry
open the differential safety piece (5) and re-
move the differential bolt (6) and nut (7), sep-
arate the differential case (8)(9),
 Take out the differential side gear (10), differ-
ential side gear shim (11), cross shaft (12),
planetary gear (13) and planetary gear shim
(14).
Tightening torque of differential case nut (7):
40-50 N m; tightening torque of ring gear fixing
nut (3): 45-55 N m
NOTE
The thrust washers of the differential side gear

and planetary gear should be placed near to the
respective gear to prevent confusion.
20-20 60068042311 EN - 07/2021 - 01

Torque converter
Removing the clutch assembly 
 Remove the sealing ring (17) at both ends of

the clutch, remove the bearing (1), remove
the guard (4), gear (2), needle bearing (3) and
shim (5);
 Remove the elastic circlip (6), baffle (7), fric-
tion plate (8), partition (9) and shim(10);
 Depress the retaining ring (12) and spring
(13), remove the elastic circlip (11) and take
out the retaining ring (12), circlip (13), piston
(14), seal ring (15) and O-ring (16).
NOTE
The clutch friction plates, spacers and pressure

plates must be placed in groups.
Removing output shaft combination 
 Loosen the safety nut (1), take out the bear-

ing (2)(5), oil seal seat (3) and O-ring (4).
Tightening torque of output shaft bearing nut:
tighten nut to 65-100 N m, loosen nut, then tight-
en the nut with 10-15 N m
NOTE
Installation sequence and orientation of 2 bear-

ings.
60068042311 EN - 07/2021 - 01 20-21

Torque converter
Gearbox assembly procedure and precautions (same for manual and

electric versions)
Output gear and bearing combination
 Press-fit the bearing on a special press; 
 Snap on the retaining ring, and apply lubri-

cating oil to the mating surface.
Idler and bearing combination 
 Press-fit the bearing on a special press, then

snap on the retaining ring and apply lubricat-
ing oil to the mating surface.
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Torque converter
Idler shaft and bearing combination 
 Press the bearing on a special press.
Gear shaft and bearing combination 
 Press-fit the bearing on a special press;

 Lubricate the mating surfaces.
Torque converter housing and oil pump

combination
 Check here that the installation hole of the
torque converter casing oil pump has a 2x30°
chamfer and is rounded;
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Torque converter
 Check the flatness of this mounting surface, 
ensuring that there are no bosses, and no
flanging of the oil passage holes and bolt
holes;
 Remove two plastic plugs and check that
there are no impurities or scratches on the
mounting surface;
 Apply lubricating oil to the O-ring when as- 

sembling the oil pump assembly;
 Tighten bolts -M8×40-2 and M8×50-4 sym-
metrically to a torque of 20–25 N⋅m;
 After the oil pump is installed, check whether 

the installation port O-ring is damaged, then
use rotating rod to check whether the oil
pump can rotate flexibly.
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Torque converter
Piston assembly 
 Before assembly, use a seal to surround the

inside of the piston groove. It should rotate
flexibly without jamming, and the steel ball
should be clean without debris.
Output shaft combination

 Apply oil on the mating surfaces when press- 
fitting oil seal 12163-82131, check whether
the oil seal is flat and intact after press-fitting,
apply grease to the edge of the oil seal, and
use a guide sleeve when fitting this combina-
tion into the output shaft to prevent damaging
the edge of the oil seal;
 Tighten the nut, ensuring that the bearing ax-
ial clearance is 0, then flatten and lock the nut
along the groove of the output shaft. The out-
put shaft should be able to freely rotate after
assembly;
 Check that the output shaft and bearing are 

clean before assembly, without secondary
flanging and dents. Pay attention to the as-
sembly sequence of the two bearings (1)(2)
during assembly;
60068042311 EN - 07/2021 - 01 20-25

Torque converter
Primary oil filter combination 
 Check that the oil passage of the primary oil

filter seat is clean and free of impurities;
check that the mounting surface is free of
dents, and polish with an abrasive brick to
smooth it out;
 When tightening the nut, be careful not to de-
form the strainer.
Differential assembly
 The pairing numbers of the upper and lower 
halves of the differential case are the same,
and they must be in the same position during
assembly;
 Check that there are no burrs, flanging, etc. in 

the case, and that the lubricating oil port faces
upwards when assembling the washer;
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Torque converter
 Use a feeler gauge to check that the axial 
clearance (3) between the washer and the
case is 0.3–0.5 mm;
 Use a mandrel to check that the gears (4) ro-
tate flexibly;
 Tighten the nut (5) according to the torque re-
quirements and bend the lock washer to se-
cure it.
Clutch assembly
 Install the piston assembly into the input 
shaft assembly so that the piston can rotate
flexibly;
 Coat the screws M8x8 (2 pcs) with Loctite
271 and tighten to a torque of 15-20 N⋅m. The
end face of the screw must not protrude or be
recessed by more than 1 mm;
 After installing the return spring and spring 

seat, install the inner friction plates and outer
friction plates in an alternating arrangement,
select the desired thickness of the end plates
and insert, and clip on the circlip; finally, in-
stall in the following order the thrust ring, for-
ward (reverse) gear, needle bearing, 2 thrust
rings and 2 pcs bearings ;
 Adjust the end plate grouping so that the axial
clearance of the friction plates is 0.5–1.0 mm
(symmetric inspection with self-made plug
gauge);
 Perform charging inspection to ensure that
the piston can move backwards and forwards
without connection of the oil passage;
60068042311 EN - 07/2021 - 01 20-27

Torque converter
Machine assembly step 1

 Turn the box over (1) and check that it is 
clean and free of impurities;
 Tighten bolts (2) to a torque of 20–25 N⋅m;

 Check the mounting surfaces and sand them 
smooth. Check that the stopper is tightened
and the thread seal tape is wound properly;
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Torque converter
 Before assembly, check that there are no 
burrs or steps on the mounting holes of the
clutch assembly. The holes should be cham-
fered and rounded to avoid cutting the seal
ring;
 Check whether all seal rings of the clutch as- 

sembly are installed. After assembly, rotate
the clutch assembly and the idler shaft and
bearing combination. Rotation must be
smooth;
 Sand down the bonding surface of the box
body, and do not forget to install O-ring
15x2.4 (2 pcs) and O-ring 24x2.4 (1 pc).

 Wipe the mounting surface of the torque con- 
verter housing with a clean cloth before as-
sembly;
60068042311 EN - 07/2021 - 01 20-29

Torque converter
 Avoid knocking the mounting surface when in- 
stalling the torque converter housing;
 Cross-tighten the bolts symmetrically to a tor- 

que of 40–50 N⋅m (there are four bolt sizes:
M10×30 (4 pieces), -M10×50 (1 pieces),
M10×55 (3 pieces), and M10×75 (1 piece);
 This is the sealing surface. Check that the
surface roughness is good when assembling.
Install a bonded washer here, making sure to
differentiate it.

 When assembling the bushings, pay attention 
to their orientation. The one with the large
chamfer is assembled at the top as shown in
the figure. Select the thickness of the adjust-
ing shims at the lower end of the bevel gear
so that the backlash between the bevel gear
and output gear teeth is 0.17–0.25 mm;
 Use a magnetic gauge stand and dial indica-
tor to measure the backlash at four symmetri-
cal points along the circumference, ensuring
that the backlash is 0.17 to 0.25 mm and the
range of fluctuation does not exceed
0.05 mm. When testing, check that the dial in-
dicator gauge head is not loose. When meas-
uring, the dial indicator rod should be perpen-
dicular to the tooth surface;
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Torque converter
 Choose the thickness of the adjusting shims 
to ensure that the axial clearance of the upper
and lower bearings is 0–0.05 mm. The bolt
tightening torque is 40–50 N⋅m;
 Apply a thin and even coating of red lead 

powder to 3 consecutive teeth of the spiral
bevel gear (21-tooth). Inspect the colouring;
the colour markings must match the grinding
markings of the bevel gear.

 Check for burrs or flanging on the hole (1) 
here. There should be a noticeable tightness
when installing the filler tube;
 Sand down the box mounting surface (2) be-
fore installing the control valve assembly and
inching valve assembly;
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Torque converter
 Do not forget to install the O-rings (3); 
 Cross-tighten the bolts (4) symmetrically to a 

torque of 45–55 N⋅m;
 Cross-tighten the bolts (5) symmetrically to a
torque of 20–55 N⋅m;
 When tightening the filter (6) be careful not to
damage the surface paint.

 The bolt tightening torque (1) is 140–165 N⋅m. 
When tightening, make sure that the latch
plate is not skewed;
 Measure the normal backlash (2) between the
differential gear ring and gear shaft pair,
which should be 0.22–0.32 mm;
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Torque converter
 The torque converter should be fully assem- 
bled. Check the product installation distance
to prevent incorrect installation;
NOTE
Pay attention to the following points during in-

stallation:
● When installing, be sure to clean the parts
● When installing the clutch plate, coat the sur-
face of the clutch plate with transmission oil

● When installing the gearbox, all seals must be
replaced with new ones

● When replacing the small ring gear or the out-
put shaft, both the small ring gear and the

output shaft should be replaced as a set
● When installing the differential assembly,
make sure that the left-hand and right-hand

bearing support bolts are correctly installed
● When installing the small ring gear shaft cov-
er, pay attention to whether the left and right

cover adjustment shims are correct
● During the installation operations, the inching
valve stem should reset after the operator re-

leases the foot pedal
● When filling the working fluid, select the fluid
according to the working conditions

● Fill with working fluid. After running for 5 mi-
nutes in neutral, check that the fluid level is

within the range specified by the dipstick
60068042311 EN - 07/2021 - 01 20-33

Torque converter
Fault diagnosis
Pressure inspection ports for gearbox re- 
pair
(1) Oil pump main oil pressure port;

(2) Torque converter pressure port;
(3) Main oil pressure port;
(4) Torque converter pressure port;
(5) Inching valve inlet pressure port;
(6) Inching valve outlet pressure port;
(7) Clutch forward gear pressure port;
(8) Clutch reverse gear pressure port;
(9) Radiator inlet port;
(10) Radiator outlet port
20-34 60068042311 EN - 07/2021 - 01

Torque converter
Troubleshooting
Failure item Troubleshooting
1. Oil level is low. Check oil level and top up oil to the normal level.
2. Check whether the inching valve stem has reset.
3. Torque converter one-way wheel seized.
4. Insufficient oil in torque converter. Check oil pump wear status and oil
level.
Unable to drive or loss of ef- 5. Check whether the spring plate of the torque converter is damaged.
ficiency 6. Check lubricating oil lines for blockage.
7. Check whether the control valve is damaged. Check whether the con-
trol valve power signal is normal.
8. Friction plates seized or worn. Check for sticking, uneven contact or
warping of friction plates.
9. Bearing damaged. Replace the bearing.
1. Check whether the control valve switch signal is normal.
2. Check whether the electromagnetic control valve is working normally.
Cannot move forwards or
backwards 3. Check whether the clutch friction plates are seized or worn. Check for
sticking, uneven contact or warping of friction plates.
4. Check seals for damage.
1. Friction plates seized or worn. Check for sticking, uneven contact or
warping of friction plates.
2. Insufficient oil in torque converter. Check oil pump wear status and oil
level.
Oil temperature too high 3. Bearing damaged. Replace the bearing.
4. Check lubricating oil lines for blockage.
5. Torque converter one-way wheel seized.
7. Check whether the radiator is working normally.
1. Gasket is damaged. Replace the gasket.
Oil leakage 2. Rubber part ageing or damaged. Replace part.
3. Part damaged or cracked. Replace.
1. Oil level is low. Check oil level and top up oil to the normal level.
2. Seal rings on the input shaft assembly and piston are worn or inter-
face wedged during assembly. Pay attention when replacing and as-
Clutch pressure low and sembling seal rings.
swing too large
3. Oil pump worn. Replace oil pump.
5. Check whether the spring connecting plate is working normally.
60068042311 EN - 07/2021 - 01 20-35

Drive axle
Overview
The forklift truck drive axle is mainly used with
hydraulic transmission gearboxes or mechanical
transmission gearboxes to form the transmission
system.
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Drive axle
Main technical data

Front-wheel drive, axle body, and fixed chassis frame, float
Drive axle structure type
type
Brake type Dual front brakes, internal expansion, hydraulic
Tyre installation distance 1000 mm
Friction disc dimensions
348*76*8 mm
(height*width*thickness)
Friction disc surface area 264 cm²*4
Brake drum internal diameter 314mm
Brake drum external diameter 350mm
Brake cylinder rod diameter dt 28.58mm
Structure and working principles

Structure
The forklift truck drive axle comprises compo-
nents such as the axle housing, wheel hub, side
shaft, left and right brakes, and the brake drum.
The axle housing structure is completely moul-
ded. The side shaft is connected to the wheel
hubs by bolts. Each wheel hub is supported on
the axle housing by two tapered roller bearings.
The side shaft only takes torque sent to the
wheel hubs. Each wheel hub is fitted with an oil
seal to stop water and dust getting in or oil from
leaking out.
The forklift truck drive axle uses internal expand-
ing dual-wheel hydraulic brakes. The brakes
comprise a brake shoe, spring, brake cylinder,
clearance adjuster and floorplate. The two
brakes are installed on either end of the front
axle. One end of the brake shoe is connected
with the strut pin. The other end is connected
with the clearance adjuster. The spring and
compression spring tie rod press the brake shoe
towards the floorplate. The main brake shoe is
fitted with a hand brake lever. The secondary
brake shoe is fitted with the adjustment rod for
the automatic clearance adjuster.
Working principle
Power is transmitted via the differential in the hy-
draulic transmission gearbox to the side shafts,
which drive the wheel hubs and thus rotate the
wheels.
60068042311 EN - 07/2021 - 01 20-37

Drive axle
Service brake 
When applying the brakes while travelling for-

ward, the actuation of the brake cylinder sub-
jects the primary and secondary brake shoes to
two equal forces acting in opposite directions,
which brings the friction plate into contact with
the brake drum. The primary brake shoe is
pressed onto the clearance adjuster by the fric-
tion between the friction plate and the brake
drum. The clearance adjuster generates a force
greater than that used to actuate the secondary
brake shoe, which pushes the secondary brake
shoe, forcing the upper end of the secondary
brake shoe hard against the support pin, thus re-
sulting in greater braking force.
Reverse braking action takes place in the oppo-
site direction. The braking force is the same as
for forward braking. A Driving
B Braking
Parking brake 
The parking brake is an internal expanding me-

chanical brake that is built into the wheel brake
and shares the brake shoe and drum with the
service brake. The handbrake lever operates by
pulling on the brake cable. The lever works on
the handbrake rod via the drive shaft pin to
cause the brake shoe to move towards the
brake drum.
1 brake cylinder
2 piston
3 emergency brake
4 brake shoe
5 regulator
6 brake cable
7 brake drum
Installation and connections

 Fit the drive axle onto the chassis. Before
connecting the drive axle with the gearbox,
unscrew the installation bolts on the side shaft
and remove the side shaft. Connect the drive
shaft and the gearbox with bolts and washers.
Then, insert the side shaft into the differential
20-38 60068042311 EN - 07/2021 - 01

Drive axle
gear of the gearbox, and then fasten the side
shaft to the wheel hub with a bolt.
NOTE
Fit the paper gasket on the mating surface of the

drive axle and gearbox.
 Install the tyre through the disc wheel onto the
wheel hub using stud bolts and spherical
nuts.
Precautions for use

1. To prevent the leakage of lubricating oil, the
drive axle must not be disassembled randomly.
2. Before driving, you should add a suitable
amount of oil to the oil level plug.
3. The friction plate should be 8 mm thick. The
minimum thickness permitted is 2 mm, with the
inner surface diameter of the brake drum at
Φ314 mm and a maximum value of Φ316 mm.
You must replace the friction plate immediately if
you find it has become too worn.
4. Precautions for reinstalling drive axle wheel
hubs:
Adjust the brake clearance adjuster so that the
clearance between the brake drum and friction
disc is between 0.24 mm and 0.4 mm.
Add 100 ml of 170 3# lithium soap grease to the
cavities on either side of each conical roller
bearing.
When tightening bolt nuts, note that the rotation-
al torque of the wheel hubs should be between
9.8 Nm and 29.4 Nm after tightening. Alterna-
tively, you can go back by about 1/8 of a turn af-
ter tightening. The wheel hubs should be able to
move freely.
The tightening torque on the side shaft bolt
should be between 96 Nm to 111 Nm.
The tightening torque of the brake drum installa-
tion bolts should be between 205.6 Nm and
225 Nm.
After installing the disc wheels, the tightening
torque of the wheel installation nut should be be-
tween 470 Nm and 550 Nm.
Bleeding air from the brakes

After carrying out repair, maintenance and other
work on the truck, or after the truck has been
used for a period of time, air may enter the
60068042311 EN - 07/2021 - 01 20-39

Drive axle
truck's brake system, greatly impacting the brak-
ing performance of the truck.
NOTE
Before bleeding air, ensure that the entire brake

system is free from leaks and that there is suffi-
cient brake fluid in the storage tank.
Procedure for bleeding the air (this

is a two-person job that requires a
coordinated effort)
 Pump the forklift truck's brake pedal 5-6
times, then fully depress the brake pedal and
hold it in position.
 The other person should loosen the bleeder
screw on the left-hand side of the drive axle
using a spanner. Brake fluid with air bubbles
will flow out of the vent port. Tighten the
bleeder screw back on immediately after
bleeding the air. Repeat this process several
times until no more air comes out.
 Use the same method to bleed air from the
bleeder screw on the right-hand side of the
drive axle.
 Repeat the bleeding of air on both sides of 
the drive axle until no more air comes out.
20-40 60068042311 EN - 07/2021 - 01

Drive axle
Troubleshooting
Brake system leaking Repair
Make adjustments to the
Brake shoe clearance incorrectly adjusted
clearance adjuster
Poor braking Brakes overheating Check for slipping
Poor contact between brake drum and friction surface Readjust
Impurities attached to friction surface Repair or replace
The brake master cylinder is leaking internally Replace
Friction surface hardened or impurities attached to it Repair or replace
Bottom plate misshapen or bolts loose Repair or replace
The brakes are
Brake shoe misshapen or incorrectly installed Repair or replace
noisy
Friction surface worn Replace
Wheel bearing loose Repair
Friction surface is greasy Repair or replace
Brake shoe clearance incorrectly adjusted Regulate the adjuster
Braking is uneven Brake wheel cylinder faulty Brake shoe
Brake shoe return spring is damaged Repair or replace
Brake drum skewed Repair or replace
Brake system leaking Repair or replace
Brake shoe clearance incorrectly adjusted Repair or replace
No brake force Air in braking system Bleed air
Brake pedal incorrectly adjusted Readjust
The brake master cylinder is leaking internally Replace
Disassembly and assembly se-

quence and table of alarms and
units
Disassembly
 Unscrew the bolts and remove the side shaft.
 Unscrew the round nuts and locking plate.
Use disassembly tools to remove the wheel
hub and brake drum. Then remove the bear-
ings, oil seals, etc.
 Unscrew the stud bolts and remove the brake
unit.
Assembly
The sequence for assembly is the opposite to
the sequence for disassembly.
60068042311 EN - 07/2021 - 01 20-41

Steering system
Overview
Steering 
The steering wheel of the forklift truck operates

in the usual way. It consists of a steering wheel,
steering column, steering gear, oil pipe and
steering axle. When the steering wheel is turned
to the right, it drives the steering gear to rotate
and supply oil to the left side of the steering axle
cylinder, so the truck turns to the right. When the
steering wheel is turned to the left, it drives the
steering gear to rotate and supply oil to the right
side of the steering axle cylinder, so the truck
turns to the left. The rear wheels of the forklift
truck are steered wheels, which makes the tail
section of the truck swing out when turning.
Hydraulic steering
Steering unit 
The full hydraulic steering gear principally con-

sists of a servo valve, cycloidal pin gear clutch
pair, linkage shaft, tappet, spring piece, check
valve and other components. The rotary servo
valve consists of a valve piston, valve sleeve
and valve body, and controls the direction of the
oil flow. The valve piston is directly connected to
the steering wheel steering column. The rotor
and stator form a pair of internal meshing gears,
i.e. cycloidal pin gear meshing pair, which acts
as a metering motor during power steering to
ensure that the oil flow rate into the steering cyl-
inder is proportional to the rotation angle of the
steering wheel, and which is equivalent to a
hand pump during manual steering. The linkage
shaft and tappet connecting the rotor and valve
sleeve ensure that the valve sleeve and the rotor
are synchronised during power steering, and
serve to transmit torque during manual steering.
The role of the spring piece is to ensure that the
servo valve returns to the neutral position when
the steering wheel is not turned. During manual
steering, the check valve between the inlet and
the oil return ports draws oil in one cavity of the
steering cylinder into the inlet port via the oil re-
turn port, and then forces it into the other cavity
of the cylinder through the cycloidal pin gear
meshing pair. During power steering, the check
20-42 60068042311 EN - 07/2021 - 01

Steering system
valve ensures that oil does not flow directly from
port P to port T.
Operating principle of the steering gear

The operating principle of the full hydraulic steering gear. It is easy to see from the hydraulic
steering gear can be understood from the hy- function diagram that there are 3 working states:
draulic function diagram of the full hydraulic neutral state, left-turn state and right-turn state.
60068042311 EN - 07/2021 - 01 20-43

Steering system
Neutral state
When the steering gear is in the middle position, tral position under the action of the spring piece.
the valve piston and valve sleeve are in the neu- Oil from the oil pump enters into the interior of
20-44 60068042311 EN - 07/2021 - 01

Steering system
the valve piston through the two rows of small piston, then flows back to the oil tank via oil port
holes at the end of the valve sleeve and valve T.
60068042311 EN - 07/2021 - 01 20-45

Steering system
Right-turn state
When the steering wheel is turned to the right (or left). Because there is a maximum rotation of
(or left), it will drive the valve piston to turn right 10.5° between the valve piston and the valve
20-46 60068042311 EN - 07/2021 - 01

Steering system
sleeve, the valve piston will overcome the elastic also rotate to the right (or left) at the same angle
force of the spring piece between the valve pis- as the steering wheel. At this time, the valve
ton and sleeve, so the valve piston rotates rela- sleeve and the valve piston form a position with-
tive to the valve sleeve. At this time, the valve out relative rotation angle, closing the oil pas-
piston oil groove is connected to the inlet circuit sage to the rotor and cylinder, so that the oil ex-
of the valve sleeve, and the oil supply from the iting the oil pump passes via port P into the inte-
pump flows through the valve sleeve and valve rior of the valve piston through the two rows of
piston oil groove to the rotor and stator, pushing small holes at the end of the valve sleeve and
the rotor relative to the stator. At the same time, valve piston, then flows from the oil return hole
oil exiting the rotor and stator passes through of the valve sleeve back to the oil tank via oil
the valve sleeve and enters a cavity of the steer- port T. At this time, the tyres also stop rotating,
ing cylinder through port A (or B), so that the pis- which is the hydraulic feedback servo action.
ton rod of the cylinder extends (retracts) and the
When the engine is switched off or the steering
steering wheel turns to the right (or left). The oil
oil pump fails (when the steering wheel is turned
in the other cavity of the oil cylinder enters the
by hand), the steering gear can be used for hy-
valve sleeve from port B (or A) and, after flowing
drostatic steering by turning the steering wheel
through the oil return groove of the valve piston,
by hand. When the steering wheel is turned to
returns to the tank from the oil return hole of the
the right (left), the valve piston turns through an
valve sleeve via port T, thereby achieving the
angle of 10.5°, and the tappet drives the rotation
steering function.
of the valve sleeve, linkage shaft and rotor. At
When the relative rotation angle of the valve pis- this time, the rotor and the stator act as a pump,
ton and valve sleeve is about 1.5°, the oil circuit whereby the rotation of the rotor sucks the oil
starts to become connected, the rotation of the out through oil port T, through the check valve,
rotor makes the oil flow to the cylinder, and the valve sleeve and valve piston into the oil inlet
amount of oil supplied is proportional to the rota- cavity of the rotor pump. Due to the action of the
tion angle of the steering wheel. hand-rotated rotor pump, the oil generates pres-
sure and enters a cavity of the steering cylinder,
When the steering wheel is turned to the right
so that the piston rod extends (retracts), the
(or left) at the same angle, the oil coming from
wheels turn to the right (left), and the oil in the
the oil pump drives the rotor to turn right (left)
other cavity passes from port B (A) through the
due to the opening of the above-mentioned oil
valve sleeve and valve piston to the oil inlet cavi-
passage. When the rotation angle of the rotor is
ty of the rotor pump via the check valve, continu-
the same as the rotation angle of the steering
ously filling the large (small) cavity to achieve
wheel, because the valve sleeve and rotor are
steering.
mechanically connected through a linkage shaft
and tappet, the rotor drives the valve sleeve to
Steering gear parameters

Displacement 100 ml/r
Maximum inlet pressure 17.5 MPa
Maximum continuous back pressure 2.5 MPa
Power steering torque 1.2–1.4 N⋅m
Precautions for steering device installation and usage

● You must ensure that all components are ● You must ensure correct installation between
clean and prevent dirt from getting into the in- the steering unit valve block oil port and the
terior of the steering device or hydraulics sys- steering unit oil port.
tem. ● When installing the steering unit, you must
● The oil port pipe joint connections must be ensure that the steering unit input port does
clean. Do not use thread seal tape instead of not come under axial force.
sealing rings to create seals.
60068042311 EN - 07/2021 - 01 20-47

Steering system
● You must bleed air from the steering unit load ● When assembling the linkage shaft and the
port. rotors, you must note the correspondence be-
● Do not disassemble the steering unit unless it tween their markings.
is absolutely necessary. You should only dis- ● You must ensure that you also install the one-
assemble the steering unit after confirming way valve steel balls and tappet. Do not incor-
what the malfunction is. rectly install a stud bolt at this position.
● Do not disassemble the combination valve ● When fitting the stud bolt, you must ensure
unless it is absolutely necessary. You must that it is tightened evenly and that its torque is
use testing equipment to adjust the internal set to between 45 and 50 N•m. Otherwise, it
pressure of the combination valve block. will easily produce dead spots and heavy
● When disassembling the steering device, you steering.
must ensure that all components are clean ● The maximum permitted amount of manual
and prevent them from getting knocked. steering torque on the steering unit is
● When disassembling the valve pistons and 136 N•m.
sleeves, you must take extra care to remove
or insert them vertically to prevent the tappet
from coming out.
Steering gear troubleshooting

Steering gear leaking oil nal flow rate of the steering gear, which prevents
the build-up of pressure in the system pressure,
Cause: the rubber ring at the journal is dam- thereby resulting in heavy steering;
aged, or the rubber ring at the relief valve is
damaged, or the connecting location of the valve Remedy (2): Replace the oil pump;
body, spacer disc, stator and back cover is leak- Cause (3): The check valve ball and valve seat
ing oil. are not tightly sealed due to impurities; the
Remedy: Replace the rubber ring or clean the check valve ball has fallen between the valve
connecting surface if dirty; if there are scratches, sleeve and the valve body ring groove; or the
grind them smooth, and tighten the bolts (when ball is worn, preventing the check valve from
tightening the 7 bolts on the back cover, fasten closing tightly during power steering and causing
every second bolt in turn, tightening gradually to the inlet and outlet oil lines to connect;
a torque of 40–50 N⋅m). Remedy (3): Replace the check valve;
Cause (4): The safety valve of the steering gear
Steering wheel turns heavily when idling opens prematurely. One possibility is that the
with light load spring of the safety valve is broken or deformed;
the other possibility is that the valve piston is
Cause: The pressure of the system relief valve
stuck due to impurities;
is lower than the working pressure of the steer-
ing system, or the relief valve has seized due to Remedy (4): Replace the safety valve or safety
dirt. valve spring; alternatively, clean the impurities
between the valve piston and valve sleeve.
Remedy: Adjust the system relief valve pressure
to the specified value. If the relief valve has
seized due to dirt, clean the relief valve. Serious steering drift
Cause: The two-way buffer valve is malfunction-
Heavy steering ing (the steel ball is stuck due to dirt or the
spring is defective).
Cause (1): The oil tank level is low, the suction
filter is blocked or the oil viscosity is too high; Remedy: Clean the two-way buffer valve or re-
place its spring.
Remedy (1): Top up oil to the specified oil level,
clean or replace the filter insert, and use recom-
mended oils; No manual steering when turning the steer-
Cause (2): Excessive wear of the oil pump, ex-
ing wheel
cessive internal leakage, or reduced volumetric Cause: The oil viscosity is too low.
efficiency. When the system is operating, the oil
supply from the oil pump is less than the nomi-
20-48 60068042311 EN - 07/2021 - 01

Steering system
Remedy: Use recommended steering hydraulic
oil.
Steering axle
Overview
The steering axle is a horizontal cylinder steer-
ing axle. Together with the forklift steering unit, it
forms the steering system. The tyres are attach-
ed to the hubs on both sides of the steering axle
for steering the vehicle.
Steering axle beam: The axle beam is cast from
high-strength ductile iron, with a tensile strength
of over 450MPa and an elongation percentage
of over 15%. The KW casting process imported
from Denmark can cast the part in one piece,
withstanding the alternating loads and impact.
Conical bearing steering mechanism: The axle
stub is fitted on the steering axle beam by two
sets of dual tapered roller bearings. It has excel-
lent rigidity and is easy to maintain, effectively
replacing the original kingpin, bearing needle
roller and thrust bearing, which are prone to
faults.
Steering cylinder: The double sealing structure
can effectively prevent oil leakage. The steering
axle has an open end, and the steering cylinder
is fitted inside the steering axle beam by four
M1×1.5 stud bolts, which is easy to install and
maintain.
Troubleshooting
Oil seepage from the cylinder port Replace O-ring
Oil seepage at both ends of the cyl-
Replace the seals
inder
Disassemble the cylinder Clean and change the piston seal
Weak or failure to steer
Oil seepage from the base of the
Replace the cylinder
grease nipple
Surface of the piston rod is scratch-
Replace the cylinder
ed
The spherical bearings at both ends
of the connecting rod are insuffi- Fill with grease
ciently lubricated
Connecting rod is jammed
The spherical bearings at both ends
of the connecting rod are contami- Replace the spherical bearing
nated
The tightening torque of the kingpin
Stub axle does not rotate lock nut is too high Adjust as required
freely
Bearings insufficiently lubricated Fill with grease
60068042311 EN - 07/2021 - 01 20-49

Steering system
Wiper ring is defective, bearing is

Change the wiper ring
contaminated
The slotted lock nut is not loosened
Adjust as required
Hub jams when rotating by 1/8–1/6 turn after tightening
Bearings insufficiently lubricated Fill with grease
Key points of maintenance and assem-

bly
The steering axle principally consists of the axle
beam, steering cylinder, stub axles, connecting
rods and steered wheel hubs. During use, install
the steel rings on the wheel hubs at both ends,
and use the hub bolts and hub nuts to connect
and fasten them. Then connect the truck frame
through the retainer plates at the front and rear
ends of the axle beam. The retainer plates are
fixed onto the frame with rubber insulating
pieces.
When the forklift truck is steered, the two ends
of the horizontal cylinder reciprocate, driving the
stub axles at both ends to rotate around the
kingpin of the stub axle, which causes the
wheels to steer the truck.
The steering cylinder is a double-acting cylinder
that is connected to the cylinder interface via two
hydraulic oil pipes. When the hydraulic system is
in operation, the piston rod of the steering cylin-
der reciprocates in the axial direction and the
connecting rod drives the rotation of the stub
axle.
The steering axle beam has an H-shape cross-
section and is cast from high-strength ductile
iron. Use top/bottom tapered roller bearing for
rotating the axle stub.
Precautions for use

● To avoid oil leakage from the steering cylin- ● When assembling, fill the wheel hub bearing
der, the steering cylinder should not be disas- and axle stub bearing with #3 lithium soap
sembled and reassembled unnecessarily. grease. The filling quantity is 1/3 to 1/2 of the
● When installing the steering axle, make sure bearing cavity.
to check whether the grease in the lubrication ● When assembling the round nut inside the
part is full. wheel hub axle stub assembly, tighten the
● When assembling the wiper ring, apply round nut with a 210–250N.m torque first,
grease evenly on the lip. then release 1/8–1/6 turns. Then, install the
round nut and use the locking plate to snap
● When assembling the hub bolts with the hub,
the clamp into the slot in the round nut. Install
they should be press-fitted or knocked in with the outer round nut with a tightening torque of
a copper hammer. 10–20N.m and then snap the clamp of the
● When using the round nut and locking plate locking plate into the corresponding slot in the
inside the axle stub, proceed in strict accord- outer round nut.
ance with the standard specifications.
20-50 60068042311 EN - 07/2021 - 01

Steering system
● The starting force of the hubs is controlled be- ● The tightening torque of the cylinder retaining
tween 20 and 50N; bolts is 210–230 N.m. Apply anaerobic threa-
● The starting force of the hubs is the force that dlocker when tightening.
causes the hubs to start rotating. To deter- ● Tighten the prevailing torque nut (8) for the
mine this force, hang a spring balance on the steering knuckle kingpin with a 97–113N.m
hub bolt and read the value when the hub torque first and then release 1/8–1/6 turns.
starts to rotate. Tighten again with a 5–10N.m torque, install
the split pin (28) and secure.
60068042311 EN - 07/2021 - 01 20-51

Steering system
Steering axle structure
20-52 60068042311 EN - 07/2021 - 01

Steering system
No. Designation Quantity No. Designation Quantity

1 Hub cap 2 18 Steering cylinder 1
2 Nut 'M30x2 2 19 Axle stub 'left 1
3 Nut M14x1.5 16 20 Bolt 6.3x80 2
4 wheel hub 2 21 Washer 2
Conical roller bearing
5 Bolt M14x1.5x42-10.9 16 22 2
30207
6 Axle stub 'right 1 23 2
30211
7 Limit stop 4 24 Oil seal 2
lubricating nipple (cone)
8 Nut '1″-14UNS-2b 2 25 4
AM6
9 Bushing 2 26 4
33206
10 Seal 2 27 Seal 'FB44x72x6 2
11 Retainer plate 2 28 Split pin 3.2x40-ST-ZNS 2
12 King pin 2 29 Bearing GE16ES 2
13 bolt 2 30 spring washer 4
14 connecting rod 2 31 Hexagon bolt 4
15 Limit stop 2 32 O-ring 25X2.65-G-N 2
Bolt
16 Bolt 4 33 4
M16X1.5X62(25)-10.9
17 Axle beam assy. 1 34 spring washer 4
Disassembly
Disassembly order:
 Remove the wheel hubs
Use a flat head hammer to remove the hub cap
((1)), then remove the M30×2×10 round nut and
locking plate in that order. You can then remove
the hub, including the pair of tapered roller bear-
ings (30209, 30207) inside and the skeleton oil
seal 75×100×10.
 Remove the connecting rods
Use a wrench to remove the stud bolt (24) and
apron (27). Punch out the connecting rod bolt
with a drift punch and then you can remove the
connecting rod.
 Remove the kingpins
Use open mouth tongs to remove the split pin
((28)) and castellated nut ((8)), remove the bear-
ing bushing ((9)) and use a copper rod to punch
out the kingpin from the axle in a bottom-to-top
direction.
 Remove the stub axles
After the kingpin is removed, the axle stub (or
the axle stub wheel hub assembly) can be taken
out.
60068042311 EN - 07/2021 - 01 20-53

Steering system
 Remove the cylinder
Loosen the four M14X1.5 bolts to remove the
cylinder.
Assembly is carried out in the opposite order to
disassembly.
20-54 60068042311 EN - 07/2021 - 01

Brake system
General information
Braking
There are 2 types of brakes: the parking brake
and the service brake. The parking brake princi-
pally comprises the parking brake pedal, parking
brake connecting mechanism, pedal unlocking
device, the brake and brake drum. The service
brake system principally comprises the brake,
brake drum, brake pedal, brake master cylinder,
brake fluid line, brake fluid cup and the parking
brake.
60068042311 EN - 07/2021 - 01 20-55

Brake system
Service brake
Service brake
Service brake schematics
1 Brake pedal 7 Brake wheel cylinder piston

2 Brake master cylinder push rod 8 Brake drum
3 Master cylinder 9 Right brake shoe assembly
4 Brake fluid cup 10 Left brake show assembly
5 Brake line 11 Brake adjustment bolt
6 Brake wheel cylinder
When the brake pedal is depressed, the lever-

age principle moves the brake master cylinder
push rod, which causes the pistons inside the
brake master cylinder to move. This creates oil
pressure that makes the pistons inside the brake
wheel cylinder move, thereby stretching out the
brake friction plates and causing them to create
friction against the brake drum.
20-56 60068042311 EN - 07/2021 - 01

Brake system
Service brake layout diagram
1 Brake fluid cup 3 Brake pedal

2 Brake master cylinder 4 Brake line
60068042311 EN - 07/2021 - 01 20-57

Brake system
Brake fluid cup 
The brake fluid cup is stored in the brake fluid

reservoir.
NOTE
Under normal usage, brake fluid will contain

spoilage and contamination, so it must be regu-
larly checked, topped up and replaced.
The brake master cylinder

This device transforms kinetic energy into hy-
draulic energy.

When the brake pedal has not been depressed,
the pistons and the seals with be in between the
two gaps. The brake fluid in the brake oil reser-
voir will be in a balanced state with the brake flu-
id in the master cylinder, brake cables, and sub-
pump.
20-58 60068042311 EN - 07/2021 - 01

Brake system

When depressing the brake pedal, the push rod
pushes the pistons and seals in the brake mas-
ter cylinder so they move past the first hole in
the master cylinder housing. The working oil
cavity in front of the pistons is sealed and the oil
pressure rises. Brake fluid enters the sub-pump,
which pushes the sub-pump piston into motion.
60068042311 EN - 07/2021 - 01 20-59

Brake system
Parking brake
Parking brake
1 Parking brake locking/unlocking device 3 Parking brake linkage structure

2 Parking brake pedal
20-60 60068042311 EN - 07/2021 - 01

Chassis and bodywork 30
Basic structure
Counterweight 
The counterweight(1) is designed to maintain

the truck's stability and consists of a large piece
of cast iron added to the rear of the truck.
Tightening torque of counterweight bolts: 1315 ±
10% N⋅m
NOTE
● Choose appropriate lifting equipment when
lifting the counterweight;
● When lifting the counterweight, you must se-
lect a sling that has a load capacity of at least
twice the weight of the counterweight.
DANGER
The lifting personnel should stand to one side, away

from the counterweight.
DPF light and switch
NOTE
The chapter is only applicable for forklift with

Doosan engine.
The HEST (high exhaust system tempera- 

ture) light
The HEST (high exhaust system temperature)
light comes on up during regeneration periods.
This light notifies the driver when hot exhaust
gas is vented from the engine. Ensure that there
is no combustible material around the exhaust
pipe.
60068042311 EN - 07/2021 - 01 30-1

Basic structure
“DPF reprocessing request” indicator light 
The “DPF reprocessing request” indicator light

(1)will flash when forced or service regeneration
is needed. This light will come on when starting
forced or service regeneration.
When the driver disables regeneration, this indi-
cator light (2) will appear.
Forced regeneration (manual regeneration) 
The driver can use these switches to activate or

disable forced regeneration.
1 DPF forced regeneration switch

2 DPF regeneration disabled switch
30-2 60068042311 EN - 07/2021 - 01

Design and labbeling

Nameplate
Variant 1: Industrial trucks built up to 
12/2021
1 Model
2 Production number
3 Year of manufacture
4 Tare weight in kilograms
5 Maximum permitted battery weight in kilo-
grams (only for electric trucks)
6 Minimum permitted battery weight in kilo-
grams (only for electric trucks)
7 Ballast weight in kilograms (only for electric
trucks)
8 For more detailed information, refer to the
technical data in the operating instructions
9 CE labelling
10 Nominal drive power in kilowatts
11 Battery voltage V
12 Rated capacity in kilograms
Variant 2: Industrial trucks built after 

12/2021
1 Model
2 Production number
3 Year of manufacture
4 Tare weight
5 Max. battery weight/ Min. battery weight
(only for electric trucks)
6 Ballast weight (only for electric trucks)
7 For more detailed information, refer to the
technical data in the operating instructions
8 Conformity marking: CE mark for the mar-
kets of the EU, the EU candidate countries,
the EFTA States and Switzerland; UKCA
mark for the United Kingdom market; EAC
mark for the Eurasian Economic Union mar-
ket
9 Rated drive power
10 Battery voltage
11 Rated capacity
NOTE
● It is possible for there to be multiple conformi-
ty markings on the nameplate.
● The EAC mark may also be located in the im-
mediate vicinity of the nameplate.
60068042311 EN - 07/2021 - 01 30-3

Load centre distance and load ca-

pacity
Before lifting goods, the relationship between
the weight, load centre of gravity distance and
maximum lift height of the goods must be under-
stood.
Load centre distance refers to the distance be- 
tween the vertical plane of the fork arms and the
centre of gravity of the loads(1).
NOTE
The centre of gravity of a load is not necessarily

located at the central point of the load itself. The
load capacity refers to the weight of goods able
to be lifted to a specified height within a given
load centre distance.
NOTE
Check the load limits. In the following circum-

stances, please contact your authorised dealer
before operating.
● Before lifting irregular loads or goods that
sway.
● Where the load centre of gravity distance is
excessively long.
● Before using attachments.
Capacity chart 
DANGER
The parameters in the load capacity diagram apply to
compact, uniform loads. These load limits must not
be exceeded. Exceeding the load limits will affect the
stability of the forklift truck and the strength of the lift
mast.
Refer to the CAPACITY CHART before lifting goods.
If attachments are fitted, refer to the load rating label
for the attachment.
For example:
Truck model: KBD25 with single tyre
Load centre: 500 mm
Lift height: ≤5000 mm
 Draw a vertical line from the 500 mm load
centre of gravity distance coordinate to where
it crosses the diagonal line representing the ≤
5000 mm lift height.
 The reading at the point where the coordinate
intersects with the horizontal line that passes
30-4 60068042311 EN - 07/2021 - 01

through this point of intersection is the maxi-
mum permitted load.
 In this case, the reading for the maximum per-
mitted load is 2500 kg
Corresponding loads relative to other lift heights
and load centre of gravity distances can also be
obtained in this way. This value relates to an
evenly distributed load on two fork carriages.
60068042311 EN - 07/2021 - 01 30-5

Location of decals
30-6 60068042311 EN - 07/2021 - 01

NOTE
The labels mentioned below are only for illustra-

tion purposes, please rely on the decals adher-
ing to your own truck.
1 Warning sign: Do not stand underneath the 14 Warning sign: Danger due to overheating of
fork/Do not stand on the fork/Do not enter radiator
space behind the mast/ Injury to hand 15 Warning sign: Danger due to shearing / Dan-
2 Decal information: Capacity rating plate ger to the driver’s head with engine hood not
3 Decal information: Acoustic power level fully closed.
4 Manufacturer’s name 16 Warning sign: Do not allow water to inlet
5 CE label Only applicable for CE 17 Warning sign: Always lifting by lifting gear at-
certificated forklifts tachment point
6 Decal information: Caution / Fasten the 18 Warning sign: Preventing water into the elec-
wheel trical parts
7 Decal information: Caution / Loosen and in- 19 Warning sign: Danger due to shearing
flate the wheel according to the instruction 20 Nameplate
8 Decal information: Caution / Read the operat- 21 Model information
ing instruction 22 Model information
9 Decal information: Lifting gear attachment 23 Decal information: Caution/Read the operat-
point ing instructions/Fasten the seat belt/Apply
10 Decal information: Filling in gasoline or diesel the parking brake when leaving the truck/
11 Decal information: Hydraulic oil tank Passengers are not allowed/Do not jump off
12 Decal information: Adding coolant if the truck is tipping over/Brace feet/Hold on
13 Decal information: Caution / Danger due to tight/Lean in the opposite direction to which
shearing the truck is tipping
60068042311 EN - 07/2021 - 01 30-7

30-8 60068042311 EN - 07/2021 - 01

Driver's compartment 40
Attachment parts interior

Bonnet 
The bonnet of the forklift truck is a component

for assembling the driver's seat that can reduce
noise and protect the engine and other parts.
NOTE
The bonnet can be removed when carrying out

repairs or maintenance on the forklift truck.
● To open the bonnet, press the bonnet lock
down. Be careful not to bump your head as

the bonnet lifts.
● To close the bonnet, press the red button in-
wards while lowering the bonnet. Be careful

not to bump your head or catch your hand as
the bonnet lowers.
1 Bonnet lock
2 Self-locking gas spring
60068042311 EN - 07/2021 - 01 40-1

Attachment parts interior
Seat (seat belt) 
Move the seat backrest forwards or backwards

until a comfortable position for the driver is
found. When the forklift truck is being operated
(when driven or during lifting etc.), the driver
should remain in the seat and lean back onto the
backrest. The automatic latch in the retractor will
ensure that the driver has sufficient freedom of
movement when operating the truck.
NOTE
● The seat belt must be worn at all times when
the truck is being driven;
● The seat belt must only be used by one per-
son at any time;
● Replace the seat belt immediately if it is de- 1 Seat belt retractor
fective; 2 Weight adjustment roller
● When replacing the seat belt retractor, pay at- 3 Seat forward/back adjustment handle
tention to the mounting angle of the retractor; 4 Backrest angle adjustment handle
5 Seat belt buckle
● When installing the seat, make sure it slides
smoothly on the forwards/backwards adjust-
ment rails and that the adjustment handle can
be firmly engaged.
40-2 60068042311 EN - 07/2021 - 01

Display-operating unit
Display unit
1 “SCR error” indicator light 9 “Water separator light” indicator light

2 Seat indicator light 10 ”DPF regeneration disabled“ indicator
3 Indicator light for "glow plug preheating" light(Red light)
4 Neutral Position indicator 11 ”Battery charging“ indicator light
5 ”Torque Converter Oil Temperature“ indicator 12 "Engine error light" indicator light(Red light)
light 13 DPF regeneration indicator light/Exhaust
6 ”Parking brake“ indicator light temperature warning light(Yellow light)
7 ”Clogged air filter” indicator light 14 “DPF regeneration request” indicator
8 ”Engine oil pressure“ indicator light light(Yellow light)
60068042311 EN - 07/2021 - 01 40-3

Operating devices
Overview of the driver’s compartment
1 Steering wheel 7 Direction selection lever

2 Parking brake pedal 8 A4 paper folder
3 Accelerator pedal 9 Lighting and direction indicator switch
4 Driving brake pedal 10 Operating lever
5 Inching pedal 11 Display unit
6 Seat 12 Cup holder
40-4 60068042311 EN - 07/2021 - 01

Operating devices
60068042311 EN - 07/2021 - 01 40-1

60 Electrics
Wiring
Diagram of main harness
60-2 60068042311 EN - 07/2021 - 01

Electrics 60
Wiring
Lin
e
Line Wire diameter Line
Start end Terminal end len
number mm2 colour
gth
mm
Connected to electric
J11 1
Connected to tail box
1 J1 Brown
light harness Connected to reversing
J24 1
beeper
Connected to right
J42 overhead guard har- 1
ness
Connected to tail Connected to steering Green/
3 J1
light harness J34 switch/combination 1 white
switch
Connected to left over-
J27 1
head guard harness
Connected to right
J42 overhead guard har- 1
Connected to tail ness Green/
4 J1
light harness Connected to steering yellow
J34 switch/combination 1
switch
Connected to function
J9 1
selector switch
Connected to right
J42 1
overhead guard
Lifting/unloading sole-
J38 1
noid valve
Connected externally to
J37 1
diode
Connected to reversing
J32 1
switch
Connected to horn
J31 1
switch
Connected to spare
J30 1
end
Connected to tail
e J1 Connected to hand- Black
light harness J29 1
brake
J27 1
head guard
Connected to alarm
J25 1
beeper
J24 1
beeper
Connected to horn
J23 1
switch
Lifting/unloading sole-
J20 1
noid valve
Connected to direction
J17 reversing solenoid 1
valve
60068042311 EN - 07/2021 - 01 60-3

60 Electrics
Wiring
Connected to air filter

J35 0.75
sensor
Connected to control
J11 1
compartment
Connected to bonding
J10 2.5
strap
Connected to seat belt
J2 1
switch
Connected to seat
J4 1
switch
J3 Connected to strobe 1
Connected to
Connected to diagnos- Yellow/
13 J8 battery positive J43 0.75
tic interface white
electrode
Connected to tail Connected to diagnos- Red/
14 J33 J43 0.75
light harness tic interface yellow
Connected to tail Connected to diagnos- Red/
e2 J10 J43 0.75
light harness tic interface blue
Connected to Connected to diagnos-
K80/K81 J18 J43 0.75
ECU on pin 91 tic interface Twisted
Connected to Connected to diagnos- pair
K80/K81 J18 J43 0.75
ECU on pin 91 tic interface
Connected to steering
J34 switch/combination 1
Connected to tail switch Green/
18 J1
light harness red
J27 1
head guard harness
Connected to tail Red/
2 J1 J12 Connected to brake 1
light harness black
Connected to Connected to spare
30 J3 J30 1 Violet
strobe end
Connected to spare
J30 1.5
end
Connected to
J3 J3 Connected to electric Grey
strobe J11 2.0
box
J12 Connected to brake 1.5
Wire diame- Line

Line Line
Start end Terminal end ter length
number 2 colour
mm mm
Connected to Connected to electric Black/
88 J3 J11 1
seat belt switch box white
Connected to Connected to electric Violet/
54 J4 J11 1
seat switch box red
J11
Connected to box White/
16 J6 1
seat belt switch Connected to display black
J36
unit
Connected to oil Connected to display Yellow/
21 J8 J36 1
level indicator unit green
Connected to Connected to battery
13 J7 J8 6 Red
generator positive electrode
60-4 60068042311 EN - 07/2021 - 01

Electrics 60
Wiring
J11
box
Connected to key
J33
switch
Connected to control
J11 1.5
compartment
Connected to
Connected to display White/
15 J11 control compart- J36 1
unit green
ment
Connected to
Connected to starter
23 J11 control compart- J21 2.5 Blue
motor
ment
Connected to key
Connected to J33 2.5
switch Brown/
14 J11 control compart-
Connected to ECU on red
ment (1.5) J18 0.75
pin 91
J27 1
Connected to head guard harness
Brown/
48 J11 control compart- Connected to right green
ment (2.5) J42 overhead guard har- 1
ness
Connected to
6 J11 control compart- J14 Connected to preheater 6 Yellow
ment
Connected to
White/
22 J11 control compart- J41 Connected to horn 1
red
ment
Connected to Connected to display
e1 J10 J36 1 Black
bonding strap unit
Connected to
Connected to ECU on Yellow/
K84 J11 control compart- J18 0.75
pin 91 blue
ment
Connected to
Connected to ECU on
K55 J11 control compart- J18 0.75 Blue
pin 91
ment
Connected to
Connected to ECU on Violet/
pin 91 red
ment
Connected to
Connected to key Green/
switch red
ment
Connected to Connected to steering
White/
51 J11 control compart- J34 switch/combination 1
blue
ment switch
Red/
white
ment switch
J37 1
Connected to diode
Red/
72 J11 control compart- Connected to direction black
ment J17 reversing solenoid 1
valve
60068042311 EN - 07/2021 - 01 60-5

60 Electrics
Wiring
J37 1
Connected to diode
Green/
71 J11 control compart- Connected to direction yellow
ment J17 reversing solenoid 1
valve
Connected to unloading
Connected to J38 1
coil Green
Connected to unloading /red
ment J20 1
coil
Connected to J38 Connected to lifting coil 1
Green/
J20 Connected to lifting coil 1 white
ment
Red/
blue
ment switch
Connected to
Connected to display Blue/
unit black
ment
Connected to
Connected to display Grey/
unit white
ment
Connected to
Connected to display Grey/
unit yellow
ment
Connected to
Connected to display Violet/
unit yellow
ment
Connected to
Connected to alarm
95 J11 control compart- J25 1 Pink
beeper
ment
Connected to
Connected to preheat-
A93 J11 control compart- J16 0.75 White
ing signal
ment
Connected to
Connected to ECU on
pin 91
ment
Connected to
Connected to ECU on
pin 91
ment
Connected to
52 J11 control compart- J29 Connected to handbrake 1
ment
Connected to
switch
ment
Connected to
switch
ment
Connected to
Connected to function
E04 J11 control compart- J9 1
selector switch
ment
Connected to wa- Connected to ECU on
K44 J5 J18 0.75
ter trap sensor pin 91
60-6 60068042311 EN - 07/2021 - 01

Electrics 60
Wiring
Connected to wa- Connected to ECU on

K48 J5 J18 0.75
ter trap sensor pin 91
Connected to fuel
Connected to ECU on
K28 J13 temperature sen- J18 0.75
pin 91
sor
Connected to fuel
Connected to ECU on
K32 J13 temperature sen- J18 0.75
pin 91
sor
Connected to ac- Connected to ECU on
K07 J15 J18 0.75
celerator pedal pin 91
K24 J15 J18 0.75
K25 J15 J18 0.75
K26 J15 J18 0.75
K27 J15 J18 0.75
K41 J15 J18 0.75
Connected to tor-
que converter oil
0 J19 J36 Connected to display unit 1
temperature sen-
sor
Connected to Connected to ECU on
e2 J10 J18 0.75
bonding strap pin 91
K76 J22 J18 0.75
MAF sensor pin 91
K79 J22 J18 0.75
MAF sensor pin 91
K86 J22 J18 0.75
MAF sensor pin 91
K87 J22 J18 0.75
MAF sensor pin 91
Connected to J31 Connected to horn switch 1
50 J23 Orange
horn switch J41 Connected to horn 1
Connected to
Connected to ECU on
K47 J26 DPF temperature J18 0.75
pin 91
sensor
Connected to
Connected to ECU on
K50 J26 DPF temperature J18 0.75
pin 91
sensor
Connected to air
20 J35 J36 Connected to display unit 0.75
filter sensor
Connected to
Connected to ECU on
K42 J28 DPF pressure dif- J18 0.75
pin 91
ferential sensor
Connected to
Connected to ECU on
pin 91
ferential sensor
Connected to
Connected to ECU on
pin 91
ferential sensor
60068042311 EN - 07/2021 - 01 60-7

60 Electrics
Wiring
Connected to re- Connected to ECU on

K11 J39 J18 0.75
generation switch pin 91
Connected to re-
Connected to ECU on
K10 J40 generation inhibit J18 0.75
pin 91
switch
Connected to dis- Connected to ECU on
K30 J36 J18 0.75
play unit pin 91 Twisted
Connected to dis- Connected to ECU on pair
K31 J36 J18 0.75
play unit pin 91
60-8 60068042311 EN - 07/2021 - 01

Electrics 60
Electrical system components

Instrument
Technical parameters
This combination display unit is an electronic
digital display unit. It features a water tempera-
ture indicator, timer, and 14 other indicator lights
for features such as battery charge, preheating
and oil pressure. When the display unit is pow-
ered, the display unit lighting will come on.
Technical parameters
Rated voltage: 12 V DC
Operating voltage range: 8–16 V DC
Usage temperature: -20°C to 60°C
Storage temperature: -30°C to 80°C
Fuel indicator: Range 0-1/4-1/2-1; wherein the
area between the 0-1/8 marks is the red zone.
When the fuel level drops below 1/6, the beeper
will continuously sound an alarm
Water temperature indicator: 60°C–120°C. The
red zone is from 110°C and upwards. The beep-
er will continuously sound an alarm when the
water temperature reaches 110°C
Hour counter: 0–99999.9 h. Once the display
unit is powered, the chronograph on the LCD
screen shows the current accumulated operating
hours. However, it will not be recording time.
The timer will only start recording accumulated
hours when the charged battery signal output is
at a high-level state.
NOTE
● After the display unit is powered on, it will per-
form self testing. All the indicator lights should
come on for 500 ms, and the beeper will
sound once.
● Preheating, water temperature, engine oil
pressure, water-oil separation, engine mal-
function, DFP regeneration alarm, driver
warning, and regeneration status indicator
light information are all displayed on the CAN.
Warning level definitions
● Level 1: Warning lights come on but do not
flash. The beeper does not sound;
● Level 2: Warning lights come on but do not
flash. The beeper emits a continuous warn-
ing. The warning sound is intermittent at a fre-
quency of 1 Hz.
60068042311 EN - 07/2021 - 01 60-9

60 Electrics
Plug connector terminal
Terminal code Function Terminal code Function Terminal code Function

8-7 CAN (-) 10-6
8-6 CAN (+) 10-5 Air filter (-) 2-2
Starting switch Seat beeper
8-5 Seat switch (-) 10-4 2-1
(+) alarm (-)
Power ground Display unit
8-4 10-3 10-10
(+) lighting (+)
Parking brake Charging indi-
8-3 10-2 10-9
(+) cator (-)
8-2 Time tracker (+) 10-1 Fuel sensor 10-8
High torque
8-1 Neutral gear (+) 8-8 10-7 converter oil
temperature (-)
60-10 60068042311 EN - 07/2021 - 01

Electrics 60
Control compartment part

Control compartment
1 30 A (Control 1) 10 Start signal

2 10 A (Horn) 11 Reverse valve relay
3 15 A (Headlights) 12 Forward valve relay
4 10 A (Indicator lights) 13 Electricity control relay
5 20 A (Control 2) 14 Headlight relay
6 10 A (Control) 15 Preheating relay
7 15 A (Switch) 16 Fuel pump relay
8 10 A (Solenoid valve) 17 Spare fuse
9 5 A (Display unit)
60068042311 EN - 07/2021 - 01 60-11

60 Electrics
Port definitions
A plug definition 
Line 13 and preheating power line 6, battery

positive electrode (B+) outputs through a fuse.
B plug definition (42 insert)
Wire diameter Wire diameter

Pin Function Pin Function
mm2 mm2
Function selec-
1–2 Key switch ON 2 23 0.5
tion
Indicator light Control ground-
3 0.85 24 1.25
power supply ing
Horn power Seat beeper
4 0.85 25 0.5
supply alarm (-)
Headlight pow-
5 2 26 Grounding 1.25
er supply
Switch power
6 2 27 Generator N 0.5
supply
Display unit Reverse beeper
7 1.25 28 0.5
power supply (-)
Control power Neutral gear in-
8 1.25 29 0.5
supply dicator (+)
Headlight Seat indicator
9 0.5 30 0.5
switch (-)
Parking brake
10–11 Engine starter 1.25 31 0.5
indicator (+)
Parking brake
12 Start signal 1.25 32 0.5
warning (+)
ECU preheating Reverse switch
13 0.5 33 0.5
(-) (-)
ECU preheating Forward travel
14 0.5 34 0.5
(+) switch (-)
ECU starting
15 0.5 35 Seat switch (-) 0.5
control (-)
ECU starting Parking brake
16 0.5 36 0.5
control (+) switch (-)
60-12 60068042311 EN - 07/2021 - 01

Electrics 60
Seat belt switch

17 Start switch 0.5 37 0.5
(-)
Reverse travel
18 Spare 1.25 38 0.85
valve
Forward travel
19 Backup 1.25 39 0.85
valve
Spare control
20 0.5 40 Unloading valve 0.85
(-)
21 ECU control (-) 0.5 41 Lifting valve 0.85
Turn signal Oil pressure
22 0.85 42 0.5
lights switch (-)
C plug definitions 
The ECU's normal power supply and controlled

power supply, output via a fuse from the battery
positive electrode (B+).
Interior schematic diagrams
A Starter relay 12 V 70 A J Spare 12 V 10 A (Internal)

B Headlight relay 12 V 40 A K Forward valve 12 V 20 A
C ECU relay 12 V 70 A L Reverse valve 12 V 20 A
D Start signal 12 V 10 A M Lifting valve 12 V 10 A (internal)
E Preheating 12 V 70 A 1 Power supply conversion and switching
F Internal control 2 Direction switch/brake/seat/seat belt and
G Internal system control circuit generator N start detection and control
H Blinker (Halogen lamp and LED general) 3 Seat/seat belt based OPS testing, control
I Reverse light 12 V 10 A (internal) 4 Flash detection and timer control
60068042311 EN - 07/2021 - 01 60-13

60 Electrics
5 Handbrake warning detection output 27 Seatbelt switch 0.5 mm2 (green blue)
6 Indicator output for relevant switch signals 28 Oil pressure switch 0.5 mm2(yellow black)
7 Key switch ON position 2 mm2 (brown) 29 Seat switch 0.5 mm2 (blue red)
8 Battery (B+) 6.0 mm2 (red) 30 Handbrake switch 0.5 mm2 (red black)
9 ECU normal power supply 4 mm2 (red green) 31 Handbrake indicator (+) 0.5 mm2 (black yel-
10 Indicator light power supply 0.85 mm2 (red low)
green) 32 Seat disconnect indicator (-) 0.5 mm2 (green
11 Horn power supply 0.85 mm2 (brown white) black)
12 ECU start-up signal (+) 0.5 mm2 (brown) 33 Seat beeper alarm (-) 0.5 mm2 (pink)
13 ECU start-up signal (-) 0.5 mm2 (purple) 34 Neutral indicator (+) 0.5 mm2 (black white)
14 Starter 2 mm2 (white) 35 Handbrake alarm (+) 0.5 mm2 (yellow green)
15 Headlight switch signal (+) 0.5 mm2 (green 36 Generator N signal (-) 0.5 mm2 (red yellow)
white) 37 Direction switch forward signal (-) 0.5 mm2
16 Power supply negative terminal 1.25 mm2 (blue white)
(black) 38 Direction switch reverse signal (-) 0.5 mm2
17 Headlight power supply 2 mm2 (red blue) (blue grey)
18 ECU control signal (-) 0.5 mm2 (brown black) 39 Turn signal light 0.85 mm2 (green)
19 ECU controlled power supply 4 mm2 (red 40 Reverse beeper 0.5 mm2 (brown)
white) 41 Spare control (-) 0.5 mm2 (grey)
20 Start control signal (+) 0.5 mm2 (orange 42 Spare power supply 1.25 mm2 (blue)
black) 43 Spare power supply input 1.25 mm2(red
21 Start signal 0.5 mm2 (white) white)
22 Preheating control signal (+) 0.5 mm2 (yellow 44 Forward valve 0.85 mm2 (white blue)
orange) 45 Reverse valve 0.85 mm2 (white)
23 Preheating control signal (-) 0.5 mm2 (brown 46 Unloading valve 0.85 mm2 (white green)
black) 47 Lifting valve 0.85 mm2 (white green)
24 Preheating output 4 mm2 (yellow) 48 Control power supply 1.25 mm2 (red)
25 Control grounding 0.5 mm2 (black) 49 Switch power supply 2 mm2 (blue)
26 Function selector switch 0.5 mm2 (grey 50 Display unit power supply 0.85 mm2 (yellow)
white)
60-14 60068042311 EN - 07/2021 - 01

Electrics 60
Tail light
60068042311 EN - 07/2021 - 01 60-15

60 Electrics
6-core anti-dust, anti-moisture plug 
Port definitions
Plug con-
Line num- Port defini-
nector Line colour
ber tions
model
1 Black Earth line
Indicator
2 Green
lights
Left turn
3 Blue
signal
AMP17426
2-2 Reverse
4 Grey
lights
Brake
5 Red
lights
Right turn
6 White
signal light
Reversing lights/beeper circuit 
Working procedure:
When the key switch is in the ON position, the
control compartment operates and power is in-
put to the reversing lights relay through a fuse.
When the direction switch is in the reverse posi-
tion, the reversing relay activates and the control
compartment outputs power along line 1 into the
reversing beeper and reversing lights, which
causes the reversing lights and reversing beeper
to start working;
Malfunction checks:
1. Control compartment check: Use a multimeter
to check whether the fuses work and whether
the power supply is normal. When the direction
switch is in the reverse position, check that the
A Control compartment
reversing relay terminal is changing from a high B Drive direction switch
to a low level; C Reverse lights
D Reversing beeper
2. Reversing relay check: When the direction 29 Drive direction switch reverse signal line
switch is in the reverse position, check that the 1 Reverse lights power line +
relay engages;
3. Direction switch check: Check that line 29 is
at low level when the reversing switch is closed;
4. Reversing beeper/reversing lights check:
Check whether the electronics are working when
line 1 in the control compartment is outputting
power. If they aren't working, it means they have
malfunctioned;
5. Wiring harness check: Measure the wiring
harness' conductivity.
60-16 60068042311 EN - 07/2021 - 01

Electrics 60
Direction control circuit 
Working procedure:
control compartment starts working and oper-
ates the forward/reverse drive direction switch.
Line 28/29 connects with e and the forward/
reverse valve in the control compartment starts
working. A high-level signal is output from line
71/72 to the solenoid directional valve, giving di-
rectional control;
Malfunction checks:
1. Direction switch check: Use a multimeter to
test the direction switch's conductivity when it
switches directions;
to check whether the fuses are working and A Control compartment
whether the power supply is normal. Check B Drive direction switch
C Solenoid switching valve
whether the forward/reverse valve control termi-
28 Drive direction switch forward signal line
nal changes from a high level to a low level 29 Drive direction switch reverse signal line
when the direction switch is closed (forward/ 71 Solenoid valve forward signal line
reverse); 72 Solenoid valve reverse signal line
4. Directional solenoid valve coil check: Use a

multimeter to check the condition of the solenoid
valve;
Foot brake indicator/warning cir- 
cuit (you must apply the foot brake

when exiting the truck, otherwise
the warning horn will continuously
sound)
Working procedure:
The battery inputs into the control compartment
via the A02 line. When the foot brake is not de-
pressed, line 52 in the control compartment re-
mains at a continuous high level. The control
compartment continuously maintains a high-lev-
el input to the foot brake warning horn/gauge via
line 95/61. After depressing the foot brake, the
foot brake switch closes and control compart-
ment line 52 changes from a high level to a low
level. Line 95/61 in the control compartment A Control compartment
changes from a high level to a low level and the B Display unit
C Foot brake switch
foot brake alarm horn and foot brake indicator D Foot brake alarm horn
will stop. 61 Foot brake indicator signal line
52 Foot brake switch signal line
Malfunction checks: 95 Foot brake alarm signal line
1. Foot brake switch check: Use a multimeter's
continuity setting to check the foot brake switch;
60068042311 EN - 07/2021 - 01 60-17

60 Electrics
2. Control compartment check: According to foot
brake switch status, use a multimeter to check
the signal of line 52 as well as line 95/61;
3. Warning horn and gauge check: Use a multi-
meter to measure the voltage between lines 89
and 22 (when the foot brake switch is discon-
nected and connected);
Horn circuits 
Working procedure:
control compartment works and high-level power
is output to the horn via the fuses. When the
horn switch is pressed, the high-level output
from the control compartment and the low level
from the horn switch form a control circuit, there-
by causing the horn to sound.
Malfunction checks:
to check whether the fuses are working and the
power supply is normal;
2. Horn switch check: Check whether line 50 is
in a low-level state when the horn switch is de-
pressed; A Control compartment
B Horn
3. Horn check: Press the horn switch and check C Horn switch
whether the horn works when a high-level power 22 Horn power line +
state exists between lines 22 and 50. If not, it 50 Horn power line -
means that the horn has malfunctioned;
60-18 60068042311 EN - 07/2021 - 01

Electrics 60
ECU control power supply 
Working procedure:
control compartment operates and the ECU
power supply signal changes to a low state. The
battery's positive electrode inputs to the ECU re-
lay control terminal via a fuse, causing the ECU
relay to operate. The control compartment out-
puts high-level current to the ECU power supply
port via DO1, causing the ECU to operate.
Malfunction checks:
1. Key switch check: When the key is in the ON
position, check whether number 14 is outputting
at a high level;
to check whether the fuses are working normally A Control compartment
and whether the power supply is normal. Check B Key switch
C ECU
whether the ECU relay operates when the key
14 Key switch ON setting
switch is in the ON position; K88 ECU power control signal line -
K05 Power line
3. Wiring harness malfunction. K03 Power line
K01 Power line
D01 Power line controlled by the ECU
60068042311 EN - 07/2021 - 01 60-19

60 Electrics
Start up 
Working procedures (ECU working at normal

status):
When the steering switch is in neutral position,
the seat switch closes. When the safety belt
switch is closed and the key switch is in the ON
position, the control compartment operates.
When the key switch is in the START position,
the start-up signal relay inside the control com-
partment operates and the K84 terminal in the
control compartment outputs at a high level to
the ECU. Once the ECU receives the high-level
current, the control activates a circuit between
relay control terminal K55 (ECU negative start-
up signal) and K72 (ECU positive start-up sig-
nal), thereby starting up the relay. Number 23
outputs at a high level to the starter motor, which
A Battery
causes the engine to start. B Fuse wire
Malfunction checks: C Start switch
D Control compartment
1. Key switch check: When the key switch is in E ECU
F Starter motor
the ON position, check whether line 14 is output-
G Drive direction switch
ting at high level. When the key switch is in the H Foot brake switch
START position, check whether line 10 is out- I Seat switch
putting at a high level; J Seat belt switch
K84 Start signal line
2. Drive direction switch check: Use a multime- K55 Start relay signal line -
ter's continuity setting to check the switch posi- K72 Start relay signal line +
tion; 10 Start control signal line
23 Starter motor signal line
3. Seat switch check: Use a multimeter's con- 28 Drive direction switch forward signal line
tinuity setting to check the seat switch; 29 Drive direction switch reverse signal line
52 Foot brake switch signal line
4. Seat belt check: Use a multimeter's continuity 54 Seat switch signal line
88 Seat belt switch signal line
setting to check the switch;
to check whether the fuses are working and
whether the current is normal. Check start-up re-
lays and start signal relays (whether they work
satisfying start-up conditions);
6. Starter motor check: Use a multimeter to
check the starter motor relay and coil;
7. Wiring harness check.
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Electrics 60
Fuel level circuit 
Working procedure:
control compartment activates. Power is output
to the display unit via a fuse, causing the display
unit to operate. Fuel level is displayed according
to resistance changes in the fuel level sensor.
Malfunction checks:
1. Fuel level sensor check: Use a multimeter to
check the fuel level sensor resistance (requires
parameters);
2. Display unit check: Use a multimeter to meas-
ure whether the voltage output of line 21 is at
5 V;
3. Wiring harness check: Measure the conduc-
A Display unit
tivity of the wiring harness with a multimeter. B Fuel level sensor
21 Fuel level gauge signal line
Indicator light circuits 
Working procedure:
Power supply from the battery positive electrode
is output at a high level to the light switch via the
fuses in the control compartment. When the indi-
cator light switch is activated, light switch line 3
outputs at a high level to the indicator lights,
thereby causing the indicator lights to operate;
Malfunction checks:
2. Light switch check: Use a multimeter to check
whether line 3 is outputting at a high level (ability
to switch to the indicator lights);
A Lamp switch
3. Indicator light malfunction; B Control compartment
C Indicator lights
49 Indicator light power signal line
tivity of the wiring harness with a multimeter.
60068042311 EN - 07/2021 - 01 60-21

60 Electrics
Lifting circuit 
Working procedure:
When the seat and seat belt switches are
closed, and the key switch is in the ON position,
power is output from the fuse to the lifting valve,
causing the lifting valve to activate. Control com-
partment line 69 outputs at a high level to the lift-
ing solenoid valve, causing the lifting solenoid
valve to activate.
Malfunction checks:
1. Seat switch check: Use a multimeter's con-
tinuity setting to check the seat switch;
2. Seat belt check: Use a multimeter's continuity
to check whether the fuses work and whether B Lifting solenoid valve
the power supply is normal. Check whether the C Seat switch
lifting valve control terminal is changing from D Seat belt switch
high level to low level and whether the output 69 Lifting valve signal line
54 Seat switch signal line
terminal is at a high level; 88 Seat belt switch signal line
4. Lifting solenoid valve check: Use a multimeter
to check the resistance of the lifting solenoid
valve;
Lowering circuit 
Working procedure:
When the seat and seat belt switches are closed
and the key switch is in the ON position, the
control compartment operates and power is out-
put from the fuses to the unloading valve, caus-
ing the unloading valve to operate. Control com-
partment line 70 outputs at a high level to the
lowering solenoid valve, causing the lowering
solenoid valve to operate.
Malfunction checks:
1. Seat switch check: Use a multimeter's con-
tinuity setting to check the seat switch;
2. Seat belt check: Use a multimeter's continuity
3. Control compartment check: Use a multimeter B Lowering solenoid valve
to check whether the fuses work and the power C Seat switch
supply is normal. Check whether the lowering D Seat belt switch
solenoid valve terminal changes from a high lev- 70 Unloading valve signal line
54 Seat switch signal line
el to a low level and whether the output terminal 88 Seat belt switch signal line
is at a high level;
4. Lowering solenoid valve check: Use a multi-
meter to check the lowering solenoid valve re-
sistance.
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Electrics 60
Display unit circuit 
Working procedure:
When the key is in the ON position, the control
compartment operates and power is output to
the display unit via a fuse, causing the display
unit to operate.
Malfunction checks:
2. Display unit malfunction;
tivity of the wiring harness with a multimeter.
B Display unit
C Display unit negative
D Display unit positive
15 Display unit power line
Lighting circuit 
Working procedure:
The positive electrode on the battery outputs at
a high level to the lighting switch via fuses in the
control compartment. Once the lighting switch is
activated, the headlight relay inside the control
compartment operates. Line 48 then outputs at a
high level to the headlights, causing the head-
lights to operate.
Malfunction checks:
to check whether the fuses are working and
whether the power supply is normal. Once the
headlight switch has activated, check whether
the relay is working and whether the relay termi-
nal is outputting at a high level;
2. Wiring harness check: Measure the conduc- B Light switch
C Headlights
tivity of the wiring harness with a multimeter;
D Headlight control -
3. Headlight malfunction. 51 Headlight control +
49 Indicator light power line
48 Headlight power line
60068042311 EN - 07/2021 - 01 60-23

60 Electrics
Brake light circuits 
Working procedure:
When the key switch is turned to the ON posi-
tion, the control compartment starts working and
power is output to the brake switch from the
fuses. When the brake switch connects (when
the brake pedal is depressed), power is output
from the control compartment, through the brake
switch, and then into the brake lights, causing
the brake lights to activate.
Malfunction checks:
2. Brake switch check: Take measurements us-
ing a multimeter's continuity setting; A Control compartment
B Brake switch
3. Wiring harness check: Measure the conduc- C Brake lights
tivity of the wiring harness with a multimeter; 12 Switch power line
4. Brake light failure.
Turn signal light circuit 
Working procedure:
control compartment starts working. Power is
output to the blinkers via the fuses and then out-
put again to the turn signal light switch. When
the steering switch is activated, the high-level
output from the controller goes to the turn signal
lights from the steering switch, activating the
turn signal lights;
Malfunction checks:
to check whether the fuses are working, the
power is normal and the blinker is normal;
2. Steering switch check: Take conductivity
readings using a multimeter; A Blinker
B Turn signal light power line
3. Wiring harness check: Measure the conduc- C Key switch ON position relay
tivity of the wiring harness with a multimeter; D Battery positive pole (B+)
E Battery negative pole (B-)
4. Turn signal light failure. F Key switch ON position
60-24 60068042311 EN - 07/2021 - 01

Electrics 60
Preheat circuit 
Working procedure:
When the key switch is in the ON position, and
the ECU and control compartment are working
normally, the preheating relay will activate/
disconnect based on the resistance signal fed
back from the engine temperature sensor, there-
by controlling the amount of time the preheat
fuse is at a high level.
Malfunction checks:
1. Control compartment check: Check the relay;
2. Temperature sensor check: Use a multimeter
to measure the temperature sensor resistance;
3. ECU check: Use a multimeter to check the
high/low-level status of the preheat signal;
4. Wiring harness check: Measure the wiring B ECU
C Preheating wire
harness' conductivity with a multimeter.
D Preheating control signal line +
E Preheating control signal line -
A93 Preheating signal line
A01 Preheating output signal line +
60068042311 EN - 07/2021 - 01 60-25

60 Electrics
Starter batteries and accessories

Battery part
1 Battery positive electrode 3 Battery charge indicator

2 Battery negative electrode 4 Battery fixing and pressure plate bolt
Model No.: 95D31RMFD

Specifications: 12 V/60 Ah; distilled water top-up
not required; charge indicator (green: fully
charged; black/no colour: discharged)
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Electrics 60
Safety
DANGER DANGER
The battery contains sulphuric acid, which is highly The battery's outer casing is made from injection-
corrosive. moulded polypropylene, which is a highly flammable
Keep out of reach of children. Users should wear eye substance.
protection and rubber gloves when working on the Therefore, it should be kept away from open flames.
battery. Users should flush with water and seek im-
mediate medical treatment if sulphuric acid should
come into contact with the user's eyes, skin, or cloth-
ing.
DANGER
Batteries produce hydrogen and oxygen when they
recharge, which may cause explosions when ex-
posed to open flames or blocked air vents.
Therefore, batteries should be kept away from open
flames and measures should be taken to avoid short
circuits (for batteries that require distilled water main-
tenance).
Battery storage
CAUTION CAUTION
This is a charged-and-ready liquid lead acid recharge- The battery can be stored at room temperature for 3
able battery. months before it needs to be recharged;
Store the battery at a temperature of 5-25°C in a If the battery is stored for more than 3 months, you
clean and well ventilated environment. Avoid placing will need to check the voltage and start up conditions.
the battery in direct sunlight and place the battery at If the voltage and start up current are too low, then
least 2 metres away from heat sources. An ambient the battery should be good to use following a re-
temperature that is too high will have a major impact charge.
on battery performance.
WARNING
The battery must not be placed upside down or on its

side. The battery must not bumped by any machinery
or have heavy pressure placed upon it.
Installing and commissioning

CAUTION WARNING
Before installing the battery, note the safety advice on Ensure that supports and clamps are clean. Check
the battery label in order to prevent unnecessary acci- whether the fixing screw on the battery support is
dents. tightened. Insecure installation will cause damage to
the casing due to vibrations when the vehicle is mov-
ing. Do not knock the electrodes. Prevent electrodes
from coming loose and spilling battery acid. Further-
more, to prevent short circuits, do not place metal ob-
jects in contact with the battery.
60068042311 EN - 07/2021 - 01 60-27

60 Electrics
CAUTION CAUTION
You must keep the battery level during installation. Do During the commissioning process, the battery will be
not allow the battery to tilt more than 40 degrees. seriously depleted when used to supply load power to
First, connect the battery's positive electrode to the equipment that has been idling for a long time or if the
engine's positive electrode. Then, connect the bat- engine is not working normally.
tery's negative electrode to the engine's negative After running the vehicle for a long period of time fol-
electrode. lowing commissioning, the battery should be allowed
to return to charged status. All power sources should
be turned off after commissioning.
NOTE
● Fasten the clamp to the end of the electric ca- NOTE
ble, ensuring that the connecting surface be-
tween the electric cable and the battery is When cleaning, do not allow water to contact the
clean. Ensure that the positive electrode and battery's positive electrode. Otherwise, it will
the connector are connected properly before hasten the battery's self-discharge.
adding protective products such as Vaseline.
● When connecting two batteries at the same
time, they should have the same battery ca-
pacity. Otherwise, it will impact the battery
service life.
Transportation
WARNING
The battery should be held securely during the trans-
portation process. Do not allow the battery to tilt, turn
upside down, or get wet.
Charging precautions
1. Batteries that have been depleted for any va- ice life. If this is the case, you must immediately
riety of reasons during usage should be readjust the regulator voltage. If the engine output
charged in a timely manner to prevent reduced voltage is too low, you must charge the battery
performance due to battery sulfation. with a charger.
2. To prevent faults due to batteries losing too 4. When recharging the battery, you must con-
much liquid, grid growth, and lead paste spill- nect the battery charger's positive electrode to
age, do not overcharge batteries that are in use the battery's positive electrode and the battery
or that are being recharged. charger's negative electrode to the battery's
negative electrode. You must not invert the elec-
3. Under normal conditions, a rechargeable bat-
trodes when charging the battery.
tery will be recharged by the engine once it has
expended its charge. When the battery finishes Avoid maintenance on the battery when it is in
a complete discharge and recharge process, it is use and does not need any liquid topping up.
called one cycle. Continuing to use the battery if We recommend using constant voltage and a
the engine's output voltage is too high or too constant voltage method of recharging where
low, or if the battery is not sufficiently charged, the current gradually decreases. We strongly ad-
or is overcharged, will shorten the battery's serv- vise against charging with constant current.
60-28 60068042311 EN - 07/2021 - 01

Electrics 60
Maintenance
1. The battery must be fully charged before be- from outside the vehicle before selling to clients.
ing put into storage. It is best to disconnect the Negative electrodes must be disconnected from
negative electrode or close the main circuit a vehicle that is stored in a shipping, sales or
switch on stacker batteries to prevent the battery distribution warehouse.
from auto-discharging or from internal consump-
5. Under normal operation, such as not using
tion from circuits in units;
the vehicle for regular periods or overnight, you
2. For batteries that are installed and in use, re- should ensure that all electronic equipment is
move them from machines and store them in a switched off. If you are not going to use a ma-
well ventilated and dry place if they have not chine for a long period of time, you should re-
been used for a long period (usually meaning move the battery and charge it outside the ma-
more than 15 days). Recharge the battery be- chine. If you are using a battery with a generator
fore you put it out of use and recharge the bat- that is not working properly, you should recharge
tery once every 3 months. Or, turn on the engine the battery immediately after work has finished
once every 3 months and allow it to run for a to prevent damage to the battery.
long period of time to charge the battery;
6. During daily usage, it is not advisable to keep
3. You must charge the battery before storing it. a starter motor in use for more than (5 to 10 sec-
You should turn on the engines of machines that onds) because starters use a lot of current. You
have been in storage for over three months once should leave an interval of between 10 and 15
every 3 months and allow the engines to run for seconds if you use a starter several times in
a period of time to charge the batteries. When succession and make sure not to run the starter
the battery charge indicator (magic eye) displays motor for too long on each use. If the machine
in black, you must immediately charge the bat- will not start after three successive uses, you
tery from outside the vehicle with a battery should find the cause and only try starting the
charger. You must immediately recharge batter- machine again after ruling out malfunction in or-
ies that have become depleted after being stor- der to prevent too much high current discharge
ed for over half a year, otherwise battery per- causing deformation damage to the battery's in-
formance will suffer and the battery may even ternal plates.
need to be scrapped. For batteries that show
7. We recommend that customers regularly
white (on the magic eye), you should first check
check units' voltage regulators so that engine
whether this is due to the green mini balls get-
voltage can be kept within specifications and to
ting jammed inside the magic eye. You can re-
prevent battery failure due to the battery being
solve this malfunction simply by gently rocking
insufficiently charged because of excessive
the battery. The battery can no longer be used if
long-term high or low voltage discharge.
the magic eye showing white has been caused
by other malfunctions, such as the battery not
having enough electrolytes or the electrolytes NOTE
drying up.
If a battery that is installed in a unit will not work,
4. You must check battery load power status on you should remove it and perform a top up
units before shipping or sale. When the battery charge.
charge indicator (magic eye) for a battery dis-
plays in black, you must recharge the battery
Charging methods
1. DC charger: charges the battery terminal to stage usually continues for between 5 and 6
14.4 V at 1/20 of the battery's rated current ca- hours). In stage 2, the charging current is half of
pacity (A) over a 20-hour period. Continuously stage 1. The voltage continues unchanged for 2
charges for 2 to 3 hours. to 3 hours (the charging time for this stage usu-
ally lasts from 10 to 18 hours).
2. An over-discharged battery can be recharged
by using staged constant current charging. 3. Constant voltage charger: Correctly connect
Stage 1 has the DC charger set to 0.1C (C is the the depleted battery to the charger (red to posi-
battery's nominal capacity). The voltage from the tive and black to negative). Press the charge
charger to the battery lattice will be 2.4 V (this button and select the 14.4 V or 16 V charge. The
60068042311 EN - 07/2021 - 01 60-29

60 Electrics
maximum charge current must not exceed 25 A. DANGER
When charging is complete, the voltage frame
will show 0.00 and stop automatically. You must not recharge a battery that has had its cas-
ing deformed or its electrolytes dried up due to over-
4. Using DC charger + constant voltage charger: charging.
used for seriously depleted batteries that a con-
stant voltage charger cannot recognise for
charging. First, set the DC charger to 0.1C for CAUTION
3-8 hours. Then, switch to the constant voltage
Personnel who are charging batteries should take
charger and continue charging until it automati- safety precautions.
cally stops.
DANGER Carry out discharge testing after charging is

complete:
Do not let charging go unsupervised.
Use a high-rate discharge tester to carry out
high-current discharge testing. Open-circuit volt-
DANGER age must be no lower than 12.5 V; voltage for 5
times discharge for 5 seconds should be higher
Do not smoke or light fires when charging. Charging than 9 V.
must take place away from open flames and in a well-
ventilated environment. No flammable or explosive
materials must be nearby.
CAUTION
Stop charging if you find the battery over-heating,
emitting a strange (acidic) smell, or spilling acid at any
point during the charging process.
Fuse wire 
Input terminal: positive battery electrode. Output

terminal: charger and 1 control box;
Function: Protects the vehicle's main circuitry
from damage to the wiring harness and electron-
ics due to short circuit;
CAUTION
If the fuse wire is damaged, it is prohibited to short the
two ends of the fuse wire with a conductor lead.
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Hydraulics 70
General information
Basic information about the hydraulic system
The hydraulic parts include a hydraulic oil pump

(power part), a hydraulic control valve (control
part), a hydraulic oil cylinder (working part), a
hydraulic oil tank, and a hydraulic pipeline (auxil-
iary part). The hydraulic oil pump is a fixed gear
pump, and the hydraulic control valve uses an
open hydraulic system.
60068042311 EN - 07/2021 - 01 70-1

70 Hydraulics
Punp-motor unit
Model number definition
1 Serial no. 6 Design no.

2 Flange spline dimensions 7 Direction of rotation (as viewed from the shaft
3 Nominal displacement (ml/r) end)L: left-hand rotation
4 Oil port position C: oil port behind 8 Shaft extension type 5：SAE 10-tooth
the rear cover on the side of involute spline
the intermediate oil inlet 9 Installation method H: two stud bolts
5 Oil port shape 2: threaded oil in horizontal direction, cen-
port, oil inlet: G1; oil out- tre distance: 106
let: G3/4
Model no.: SGP1A32C2H5-L-463D
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Hydraulics 70
Punp-motor unit
Gear pump performance parame-

ters
Theoretical displacement: 32.4 mL/r;
Rated pressure: 20.6 Mpa;
Maximum pressure: 24.5 Mpa;
Minimum speed: 400 r/min;
Maximum speed: 3000 r/min;
Working principle 
The gear pump relies on the gear's rotary mo-

tion in an enclosed space to alternately increase
and decrease the working volume to achieve flu-
id suction and discharge.
● The volume should increase and decrease al-
ternately:
The volume of inlet ports(1) increases and the
volume of outlet ports(2) decreases.
● The oil suction chamber and oil pressure
chamber must be separate:
Three seal locations: tooth surface seal, tooth
tip and casing gauge, and "sweep chamber" be-
tween gear and casing.
60068042311 EN - 07/2021 - 01 70-3

70 Hydraulics
Punp-motor unit
Structure
1 Oil seal: Dust-proof, airtight and 5 Driven gear

leak-proof 6 Side panel: Axial clearance com-
2 Front cover pensation and sealing to en-
3 Irregular ring: Isolates high and low sure flow
pressure (20.6 Mpa). Snap 7 Intermediate body
rings are required above 8 Rear cover
20.6 Mpa to ensure flow
4 Main gear: Connected to the drive
device
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Hydraulics 70
Punp-motor unit
Precautions for use

● Due to the structure of the gear pump, it can- ● It is strictly prohibited to use force during in-
not be operated in reverse. Turn in the desig- stallation, such as by knocking or hammering
nated direction. Method: Check the data plate (do not strike with a hammer or secure the
on the gear pump: R indicates right rotation; L pump with screws, because the clearance be-
indicates left rotation; tween the stopper and the splines is very
● Check for burrs or foreign objects around the small);
mounting stopper and internal splines. Check ● Selection of working fluid: 4–430 mm²/S. Dur-
the verticality and coaxiality of the stopper ing normal operation, the temperature of the
and connection splines; when mounting the working fluid should be controlled within the
splines and stopper, slide the pump quickly range of 5°C–80°C. When it is between 80°C
and gently into the spline sleeve and mount- and 100°C, the truck can run for a short time.
ing stopper. After mounting, use a torque When it is between -20°C and 5°C, it can only
wrench to tighten to the same torque. If the be operated for a short time and without a
stopper mounting surface and the stopper load.
cannot adhere closely to each other, the gear
pump should be removed and the problem
identified. Do not fasten the pump using
screws;
Troubleshooting
Insufficient pressure Oil leakage
● No oil suction or insufficient flow; ● Wrong sized connector or seal;
● Leak in the system; ● Poor contact at the seal (due to burrs, iron fil-
● Relief valve setting too low or is defective; ings or rough contact surfaces);
● Large clearance or severe wear; ● Seal ring damaged/aged, or high temperature
failure;
● Volumetric efficiency is too low;
● Connector not vertical.
● Insufficient drive power.
Heavy wear, overheating (burnt pump)

No oil suction or insufficient flow
● Oil temperature too high (low oil volume, poor
● Direction of rotation reversed;
heat dissipation);
● Inlet and outlet port connections reversed; ● Low viscosity of oil or poor oil quality;
● Insufficient oil suction; ● Air in the system, a lot of air bubbles in the oil;
● Revolution speed too low; ● Oil return port is too close to the oil inlet;
● Oil tank level is too low; ● Small clearance, poor surface roughness of
● Filter insert is clogged or insufficient flow ca- rotating parts;
pacity; ● Revolution speed too high;
● Suction pipe is blocked; ● The working pressure is set too high.
● Suction pipe is leaking;
● The diameter of the suction pipe is too small;
Broken shaft, broken gear
● Oil level too low.
● The eccentricity between the output shaft and
the pump shaft is large;
Excessive noise
● Quality problems with materials and heat
● Speed is too fast, temperature is too low, inlet treatment;
oil resistance is too large, air is released; ● Large particles of metal and other hard debris
● Sympathetic vibration; entering the pump;
● Air infiltration; ● Too high pressure peak of system hydraulic
● Hydraulic fluid level low. shock;
● Blocked outlet port;
● Frequent starting and parking under load.
60068042311 EN - 07/2021 - 01 70-5

70 Hydraulics
Punp-motor unit
Cracked cover ● System hydraulic shock too large, resulting in
a high localised pressure peak;
● Cast faulty; ● Blocked outlet port.
● System pressure setting too high or relief
valve malfunction (jamming valve);
70-6 60068042311 EN - 07/2021 - 01

Hydraulics 70
Directional control valve

Model: FLV-95N (3691 type)
Features
● Parallel oil line gives priority function;
● Equipped with bypass unloading and median
position unloading channels;
● Easily changeable multi-part style valve
plates;
● Valve rod and valve casing interlock tightly,
minimising internal leakage;
● Excellent safety: inner design features auxili-
ary functions such as a main safety valve,
60068042311 EN - 07/2021 - 01 70-7

70 Hydraulics
auxiliary pump safety valve, charge valve and
hydraulic lock;
● Load sensitivity junction valve has steering
and braking priority;
● Good fretting performance;
● Hardly any pressure loss; small handle actua-
tion force;
● Reliable seals.
Technical data
Rated flow: 95 L/min;
Rated pressure: 250 kgf/cm2;
Maximum back pressure: 10 kgf/cm2;
Valve piston travel: 7.8 mm;
Valve piston drift diameter: Φ19 mm;
Main safety pressure:
● 2.5T:175 kgf/cm2 (75 L/min)
● 3.0T:172 kgf/cm2 (75 L/min)
● 3.5T:185 kgf/cm2 (75 L/min)
Secondary safety valve pressure:
121±3.5 kgf/cm2 (23 L/min);
Control flow rate: Tilt plate: 28+2 L/min;
Solenoid valve: Operating voltage: 12 V; A is al-
ways open; B is always closed;
CAUTION
When there is a fault with the hydraulic lock solenoid
valve, the needle valve will turn halfway around anti-
clockwise; it should not turn more than 2 full rotations.
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Hydraulics 70
About the functions of main components
1 Oil feed P 6 Non-return valve

2 Parking lock solenoid valve A 7 Pressure signal
3 Lifting lock solenoid valve B 8 Auxiliary 2 intake/return oil port
4 Main safety valve 9 Auxiliary 1 intake/return oil port
5 Auxiliary safety valve 10 Tilt oil return port
60068042311 EN - 07/2021 - 01 70-9

70 Hydraulics
1 Lifting valve rod 3 Auxiliary valve rod 1

2 Tilt valve rod 4 Auxiliary valve rod 2
70-10 60068042311 EN - 07/2021 - 01

Hydraulics 70
1 Lifting valve oil port 3 LS port

2 Oil return T port 4 Lower valve cover
60068042311 EN - 07/2021 - 01 70-11

70 Hydraulics
1 Steering inlet port 3 Control valve installation retaining bolt port 2

2 Control valve installation retaining bolt port 1 4 Control valve installation retaining bolt port 3
70-12 60068042311 EN - 07/2021 - 01

Hydraulics 70
Hydraulic line direction
1 Main oil line (from the hydraulic oil pump) 5 Steering unit line (to the steering unit)
2 Return oil line (to the hydraulic oil tank) 6 Lifting line/(to the lifting speed limit valve)
3 Tilt line (to the tilt cylinder) 7 LS line (to the steering unit LS port)
4 Auxiliary function line (to the auxiliary compo-
nents)
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70 Hydraulics
Schematic diagrams
70-14 60068042311 EN - 07/2021 - 01

Hydraulics 70
Flow divider valve structure and principles
60068042311 EN - 07/2021 - 01 70-15

70 Hydraulics
70-16 60068042311 EN - 07/2021 - 01

Hydraulics 70
Lifting function (lifting procedure)
60068042311 EN - 07/2021 - 01 70-17

70 Hydraulics
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Hydraulics 70
Lifting function （Load-keeping procedure）
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70 Hydraulics
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Hydraulics 70
Lowering function
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70 Hydraulics
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Hydraulics 70
Front tilt function
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70 Hydraulics
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Hydraulics 70
Rear tilt function
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70 Hydraulics
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Hydraulics 70
Auxiliary function (retraction process)
60068042311 EN - 07/2021 - 01 70-27

70 Hydraulics
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Hydraulics 70
Auxiliary function (extension procedure)
60068042311 EN - 07/2021 - 01 70-29

70 Hydraulics
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Hydraulics 70
Pressure control function
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70 Hydraulics
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Hydraulics 70
G-point pressure point signal
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70 Hydraulics
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Hydraulics 70
Oil intake flow rate control
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70 Hydraulics
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Hydraulics 70
Bypass oil line (prevents speed loss)
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70 Hydraulics
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Hydraulics 70
Electromagnetic parking lock
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70 Hydraulics
Precautions for installation, com-

missioning and running
● Ensure that the installation surface is level to
avoid jamming the valves due to unevenness.
● Avoid getting dirt in the interior when disas-
sembling.
● Before testing, ensure that there is hydraulic
oil in the components. First, run at low speed
under no load for 5 minutes and check that all
air is drained from the system. If you hear any
abnormal noise, check for leaks along the oil
inlet and oil line.
● Check that the control valve works at low
speed under no load. Once the actuators are
working normally, run at high speed for 6 mi-
nutes.
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Hydraulics 70
Transport and storage

● Measures should be taken to protect exposed
threads of the oil port.
● Packaging should be strong and reliable, and
measures should be taken to prevent shock
and moisture.
● Avoid storing in high-temperature and high-
humidity environments.
Adjusting the directional control 
valve pressure
Adjusting the main oil pressure
Tool specifications:
(1) 10 mm
(2) 1/8 (Imperial)
 Loosen the prevailing torque nut on the main 

oil pressure valve.
CAUTION
Do not adjust the pressure so that it is too high, or so
that the pressure adjustment screw is damaged!
 Rotate the screw either clockwise or anti-

clockwise (clockwise will increase pressure
and anti-clockwise will decrease pressure).
Make small adjustments to pressure as nee-
ded.
 Put the prevailing torque nut on once the
pressure has been properly adjusted.
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70 Hydraulics
Auxiliary safety pressure adjust- 
ment
Tool specifications:
(1) 10 mm;
(2) 1/8 (Imperial);
 Loosen the prevailing torque nut on the main
oil pressure valve.
 Rotate the screw either clockwise or anti-
clockwise (clockwise will increase pressure
and anti-clockwise will decrease pressure).
Make small adjustments to pressure as nee-
ded.
 Put the prevailing torque nut on once the
pressure has been properly adjusted.
CAUTION
Do not adjust the pressure so that it is too high, or so
that the pressure adjustment screw is damaged
Cylinder leak inspection

Method for inspecting steering cylinder in- 
ternal leakage
Turn the steering wheel all the way to the left (or
right), remove the connecting tubing on the left
(or right) side of the cylinder, then continue
steering to the left (or right). If there is oil spray
at the cylinder interface, it means that there is a
leak inside the cylinder; otherwise the cylinder is
functioning normally.
Leakage inside the steering cylinder will cause
the following phenomena:
● No stop position when steering
● Truck zigzags when travelling
● Steering drift when travelling
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Hydraulics 70
Cylinder leak inspection
Method for inspecting tilt cylinder leakage 
Tilt the mast fully backwards, remove the tubing

at the rear end of the left or right tilt cylinder, and
continue to tilt the mast backwards. Oil escaping
from the rear end of the cylinder indicates leak-
age inside the cylinder. Oil escaping from the
tubing end indicates leakage inside the other
side of the cylinder. If no oil escapes from either
side, it means that the cylinder is functioning
normally.
Leakage in the tilt cylinder will cause the mast to
tilt by itself.
Method for inspecting lift cylinder internal 

leakage
Raise the mast lift cylinder to the top, remove
the vent pipe at the upper end of the lift cylinder,
then lower the mast. Lift and lower the mast a
few more times. Oil escaping from the vent hole
at the upper end of the lift cylinder indicates
leakage inside the cylinder. If no oil escapes, it
indicates that the lift cylinder is functioning nor-
mally.
Leakage in the lift cylinder will cause the mast to
slide down by itself.
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70 Hydraulics
Flow control valve

Working principle diagram
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Hydraulics 70
Flow control valve
Structural diagram
D1 Normal flow direction 5 Valve sleeve

D2 Throttle direction 6 Throttle plate
1 Connector 7 Spring
2 Spring 8 O-ring
3 Nylon ball 9 Valve body
4 Valve piston
Working principle
The valve controls the lowering speed of the fork
and plays a safety role in the event of unexpec-
ted situations, such as rupture of pressurised oil
lines.
Oil returning from the lift cylinder enters valve G,
and returns to the directional control valve via F,
E, D, C, B and A. When a large amount of oil
flows through valve piston hole C, the pressure
difference generated by the valve piston causes
the valve piston to move to the right. In this way,
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70 Hydraulics
Flow control valve
the channel between holes D and C becomes
narrower, the return oil flow is reduced, and the
lowering speed of the fork becomes slower.
If the forks need to be lifted, pressurised oil from
the directional control valve enters the lift cylin-
der via A, B, C, D, E, F, and G.
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Lifting system 80
Lifting system
Mast specifications
2.5T MAST SPECIFICATIONS
Rated capacity height free-lift height

mast angle
max.heig load center 500mm height
mast type closed without with car-
ht double with car-
2.5t height carriage riage front/ back
tyres riage
3000 2500 2500 2080 4040 140 140
3300 2500 2500 2230 4340 140 140 6/12
3500 2500 2500 2330 4540 140 140
VM 4000 2500 2500 2630 5040 140 140 6/8
Standard
wide-view 4500 2500 2500 2880 5540 140 140 6/6
5000 2500 2500 3130 6040 140 140
5500 2500 2500 3430 6540 140 140 3/6
6000 2100 2500 3680 7040 140 140
3000 2500 2500 2080 4040 1425 1080
VFM Full 3300 2500 2500 2230 4340 1570 1230 6/12
free du- 3500 2500 2500 2330 4540 1675 1330
plex 4000 2500 2500 2630 5040 1975 1630 6/8
4500 2500 2500 2880 5540 2225 1880 6/6
4000 2500 2500 2005 5040 1280 1005
4350 2500 2500 2130 5390 1405 1130
4500 2500 2500 2180 5540 1455 1180
6/6
4700 2500 2500 2245 5740 1520 1245
VFHM 4800 2500 2500 2280 5840 1555 1280
Full free
triplex 5000 2500 2500 2423 6040 1698 1423
5400 2500 2500 2623 6440 1898 1623
5500 2500 2500 2657 6540 1932 1657 3/6
6000 1968 2500 2890 7040 2165 1890
6500 1584 1968 3123 7540 2398 2123 3/3
60068042311 EN - 07/2021 - 01 80-1

80 Lifting system
Lifting system
Rated capacity height free-lift height mast an-

max.heigh load center 500mm height gle
t double with car- front/
3.0t height carriage riage
tyres riage back
3000 3000 3000 2080 4273 145 145
3300 3000 3000 2230 4573 145 145 6/12
3500 3000 3000 2330 4773 145 145
VM 4000 3000 3000 2630 5273 145 145 6/8
Standard
wide-view 4500 3000 3000 2880 5773 145 145 6/6
5000 3000 3000 3130 6273 145 145
5500 3000 3000 3430 6773 145 145 3/6
6000 2400 3000 3680 7273 145 145
3000 3000 3000 2080 4273 1422 852
VFM Full 3300 3000 3000 2230 4573 1572 1002 6/12
free du- 3500 3000 3000 2330 4773 1672 1102
plex 4000 3000 3000 2630 5273 1972 1402 6/8
4500 3000 3000 2880 5773 2222 1652 6/6
4000 3000 3000 2005 5273 1281 777
4350 3000 3000 2130 5623 1406 902
4500 3000 3000 2180 5773 1456 952
6/6
4700 3000 3000 2245 5973 1521 1017
VFHM 4800 3000 3000 2280 6073 1556 1052
Full free
triplex 5000 3000 3000 2423 6273 1699 1195
5400 3000 3000 2623 6673 1899 1395
5500 3000 3000 2657 6773 1933 1429 3/6
6000 2528 3000 2890 7273 2166 1662
6500 2164 2688 3123 7773 2399 1895 3/3
80-2 60068042311 EN - 07/2021 - 01

Lifting system 80
Lifting system
Rated capacity height free-lift height mast an-

max.heigh load center 500mm height gle
t double with car- front/
3.5t height carriage riage
tyres riage back
3000 3500 3500 2230 4273 150 150
3300 3500 3500 2380 4573 150 150 6/12
VM 3500 3500 3500 2480 4773 150 150
Standard 4000 3500 3500 2780 5273 150 150 6/8
wide-view 4500 3500 3500 3030 5773 150 150 6/6
5000 3500 3500 3280 6273 150 150
3/6
5500 2772 3500 3580 6773 150 150
3000 3500 3500 2080 4273 1422 852
VFM Full 3300 3500 3500 2230 4573 1572 1002 6/12
free du- 3500 3500 3500 2330 4773 1672 1102
plex 4000 3500 3500 2630 5273 1972 1402 6/8
4500 3500 3500 2880 5773 2222 1652 6/6
4000 3500 3500 2005 5273 1281 777
4350 3500 3500 2130 5623 1406 902
4500 3500 3500 2180 5773 1456 952
6/6
4700 3500 3500 2245 5973 1521 1017
VFHM 4800 3500 3500 2280 6073 1556 1052
Full free
triplex 5000 3500 3500 2423 6273 1699 1195
5400 3500 3500 2623 6673 1899 1395
5500 3400 3500 2657 6773 1933 1429 3/6
6000 2476 3500 2890 7273 2166 1662
6500 1688 2776 3123 7773 2399 1895 3/3
NOTE
This data would be changed under different

working condition. Other lift heights and their
corresponding data provided separately.
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80 Lifting system
Lifting system
Duplex lift mast high lift cylinder repair pack
80-4 60068042311 EN - 07/2021 - 01

Lifting system 80
Lifting system
KEY PART PART NAME SPECIFI- APPLIED

LEV PAT NO. QTY REMARK
NO. NAME (CHINESE) CATION DATE
Lift master
Lift cylin-
6262490 cylinder as- ￫2017.9.
A 001 1 der as- 1 30.35
2100 sembly 3
sy.HY’3M
HY’3M
Lift master
Lift cylin-
6262490 cylinder as- 2017.9.4
001 1 der as- 3000 1 30.35
2142 sembly ￫
sy.HY’3M
HY’3M
Lift master
Lift cylin-
6261490 cylinder as- ￫2017.9.
002 1 der as- 1 25
2101 sembly 3
sy.HY’3M
HY’3M
Lift master
Lift cylin-
6261490 cylinder as- 2017.9.4
002 1 der as- 3000 1 25
2135 sembly ￫
sy.HY’3M
HY’3M
6262446
B 001 2 Repair kit Repair Kit 1 30.35
9701
6261320 Repair kit Repair kit as-
002 2 1 25
9500 assy. sembly
6262448 Sets of 45x57x7/ ￫2015.6.
1 001 3 Sets of seals 1 30.35
9908 seals 10 18
6262343 45x57x7/ 2015.6.1
002 3 Seal Seal 1 30.35
1305 10 9￫
Seal
6261343 40x52x7/
003 3 40x52x7/ Seal 1 25
1301 10
10
6262448 Sets of ￫2015.6.
2 001 3 Sets of seals 45x55x6 1 30.35
9906 seals 18
6262343 2015.6.1
001 3 Seal Seal 45x55x6 1 30.35
1306 9￫
6261343 Seal
002 3 Seal 40x50x6 1 25
1302 40x50x6
6262448 Sets of
3 001 3 Sets of seals 55.6x2.4 1 30.35
9907 seals
6261343 Seal
002 3 Seal 49.7x2.4 1 25
1303 49.7x2.4
6262446 56x2.5x2 ￫2015.6.
4 001 3 Ring Support ring 1 30.35
0701 0 18
6262343 2015.6.1
001 3 Ring Ring 56x51x20 1 30.35
2801 9￫
6261343
002 3 Ring Ring 50x45x20 1 25
2800
6262446 ￫2015.6.
5 001 3 Stop Stop 56x45x3 1 30.35
1406 18
6262446 2015.6.1
001 3 Stop Stop 56x45x3 1 30.35
1412 9￫
6261446 Stop
002 3 Stop 50x40x3 1 25
1402 50x40x3
6262448 Sets of ￫2015.6.
6 001 3 Sets of seals 56x45x7 1 30.35
9905 seals 18
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80 Lifting system
Lifting system
6262343 2015.6.1
001 3 Seal Seal 56x45x7 1 30.35
1308 9￫
6261343 Seal
002 3 Seal 50x40x6 1 25
1300 50x40x6
80-6 60068042311 EN - 07/2021 - 01

Lifting system 80
Lifting system
Triplex lift mast high lift cylinder repair pack (side cylinder)
60068042311 EN - 07/2021 - 01 80-7

80 Lifting system
Lifting system
6262343130 8703624010
1 001 3 Seal 45x57x7/10 Seal 45x57x7/10 45x57x7/10
5 1
6313343130 Seal
002 3 Seal DKB40x52x7/10
0 DKB40x52x7/10
6262343130 8703624020
2 001 3 Seal 45x55x6 Seal 45x55x6 45x55x6
6 1
6313343130
002 3 Seal 40x50x6 Seal 40x50x6
2
6262343130
3 001 3 Seal Seal 55.6x2.4
7
6313343131
002 3 CO 0637 Seal Seal 49.7x2.4
9
6262343280 8703628010
4 001 3 Ring 56x51x20 Ring 56x51x20 56x51x20
1 1
6313343280
002 3 27970-53141 Ring Ring 50x20x45
2
6262446141 8703628010 Stop 56 small 5
5 001 3 Stop 56x45x3 56x45x3
2 2 first
6313343132
002 3 23650-83521 Seal Seal 50x40x6
0
6262343130 8703624030
6 001 3 Seal 56x45x7 Seal 56x45x7 56x45x7
8 1
6313343130
002 3 Seal 50x40x3 Seal 50x40x3
1
80-8 60068042311 EN - 07/2021 - 01

Lifting system 80
Lifting system
Triplex lift mast high lift cylinder repair pack (middle cylinder)
60068042311 EN - 07/2021 - 01 80-9

80 Lifting system
Lifting system
1 001 3 63133431304 Dust ring Dust ring 60x74x8/11

002 3 62613431304 FQ0041CO Seal Seal 50x58x6.5
2 001 3 62623431309 89036290101 Seal 84.4x3.1 Seal 84.4x3.1 84.4x3.1
002 3 62613431305 Z6053-07443 Seal Seal 74.4x3.1
3 001 3 63133431306 89036214602 Seal 70x60x3 Seal 70x60x3 60x70x3
002 3 62614461403 22658-52301 Stop Stop 50x60x3
Spindle seal-
4 001 3 63133431307 Seal ring 60x70x6
ing ring
002 3 62613431306 24329-45591 Seal Seal 50x60x6
5 001 3 63133431308 O-ring O-ring seal 77.5x3.55
002 3 62613431307 Z6053-06903 Seal Seal 69x3.55
6 001 3 63133432801 Ring Ring D85x20x2.5
GCQ075JND-
002 3 62613432801 Ring Ring D75x69x20
05
7 001 3 63133431309 Snap ring Snap ring 85x70x3
GCQ075JND-
002 3 62613431308 Seal Seal 75x65x3
06
8 001 2 63133431310 002 85x70x9
002 2 62613431309 FU0897L0 Seal Seal 75x65x6
9 001 2 63133431311 Seal O-ring seal D15.8x2.4
10 002 1 62625040800 Spring Spring
11 001 1 62623450500 Valve piston Valve piston
12 002 1 63134461412 Stop Stop
80-10 60068042311 EN - 07/2021 - 01

Lifting system 80
Chains
Lubricating
Chain lubrication prior to factory release
The very first lubrication is intended to prevent
corrosion. (Heat and then apply oil)
Reapplying lubrication (during opera- 

tion)
The service life of a well lubricated chain can be
extended dozens of times. The key to lubrication
isn't in how much is used, but rather in enough
lubricant penetrating the main linking parts of the
chain (on the surfaces of the pins). This image
shows where enough lubricant must penetrate
between the chain linkages and the pins as well
as the narrow gaps between the chain linkages.
Lubricant
Mineral oil can be used on leaf chains under
normal temperatures. The viscosity of lubricating
oil depends on working environment tempera-
ture as well as the lubricant type.
Ambient tem- Viscosity re-

Recommended products
perature sults
>-40°C<-30°
VG15 Klüberoil 4UH 1-15 – Klüber Lubrication
C
Klüberoil 4UH 1-68N – Klüber Lubrication Anticorit LBO 160 TT –
>-30°C<+5°C VG68
Fuchs DEA
>+5°C< Klüberoil 4UH 1-150N – Klüber Lubrication Anticorit LBO 160 – Fuchs
VG150
+45°C DEA Rexoil – Rexnord Kette
NOTE
Do not use grease or lubricant that is too vis-

cous. Oils that contain graphite or molybdenum
dioxide are unsuitable because these kinds of
oils easily form grease rings (grease collars).
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80 Lifting system
Chains
Lubrication method 
The method of lubrication depends on working

conditions. With the operating speed normally
within 0.5 m/s, you can usually apply lubricant
manually with a brush or an injector. If the oper-
ating speed is between 0.5 and 2 m/s, you can
apply the lubricant by drip lubrication. You must
ensure that there is enough lubricating oil. The
lubricating oil must drip in the gaps on the sides
of the chain linkages while the chain is in opera-
tion to ensure that the lubricating oil gets right in-
to the chain.
Lubrication intervals
The chain must be lubricated for the first time
when it is first put into use. Subsequent lubrica-
tion intervals will depend on the working condi-
tion of the equipment, frequency of use, and en-
vironmental factors. Lubrication amount and in-
terval should be determined based on whether
the lubricant on the surface of the chain is wet to
the touch. There should be a thin layer of grease
on the surface of the chain to prevent corrosion
to the chain.
Storage
A layer of protective grease should be reapplied
to the chain if it has been in storage for more
than 12 months. If the chain is left unprotected,
the lubricant will be affected by dust or other
debris, which may damage the chain or its com-
ponents.
Cleaning chains
You must clean the chain if the permeability of
the lubricant becomes affected by contamination
arising through normal use. You should only use
cleaning products made from alkane derivatives,
such as diesel fuel, motor oil used in cars, and
petrol. Cold cleaners, corrosion inhibitors, and
acidic cleaners must not be used with steam
spray cleaning. These cleaning agents cause
chains to suffer from hydrogen embrittlement
more easily.
Inspection
Inspection plan
Regular inspections are essential for maximising
a chain's service life. Follow the inspection plan
set out below:
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Lifting system 80
Chains
Three month inspection
You should carry out an inspection once every
three months if the vehicle is obviously dirty and
under very high permanent load.
Yearly or fine tuning inspection plans

(items)
● Check for wear on the chain;
● Measure the actual length of the chain;
● Control and maintain the cleanliness of the
chain's components;
● Clean away dust and accumulated debris
from the chain;
● Check for signs of warping to the chain link
frame;
● Check how the chain pins turn;
● Check if external force has damaged the sur-
face of the chain;
● Check the lubrication of the chain and for
signs that the lubricant on the surface of the
chain has dried up or is clogged.
Important items for inspection:
If any of the following signs appear, you must
immediately carry out a complete inspection or
critical maintenance:
● The chain extends beyond its specified range;
● There are obvious signs or wear or corrosion
to the chain links;
● There are serious problems with lubrication;
● Equipment malfunction that causes extra im-
pact on the chain;
● There are thick dust deposits or the surface
moisture humidity is too great.
60068042311 EN - 07/2021 - 01 80-13

80 Lifting system
Chains
Control standards
Chain elongation caused by wear 
When checking a chain's wear elongation, you

must measure the bus bar on the same side with
the same type of components on the chain un-
der a definite measuring force. General leaf
chain usage allows for wear elongation to be
within 3%. That is to say: If the length of a chain
with 33 links has reached the same length as a
new chain with 34 links, the first chain has
reached its 3% rate of wear elongation.
Chain (symmetrical) tightness

When 2 chains are paired with one another, you
should inspect or adjust their tightness relative
to one another and try to keep them at the same
tightness.
Signs of surface rust

Signs of surface rust are easily visible: brown
colouring on the surface of the chain indicates
that rust is present. Pits from corrosion along the
surface of the chain indicate the possibility that
rust has become a source of fatigue. You should
apply a layer of anti-rust oil if rust occurs on the
surface of the chain.
Pin turning 
If the pins start turning, it is due to some factor

acting on the chain (such as overloading, fati-
gue, micro-abrasions). This can cause the fric-
tion fit between the pins and the chain links to
fail. You must not continue to use a chain that
has turning pins. The chain must be replaced
immediately.
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Lifting system 80
Chains
"Dead links" 
If a chain cannot be returned to its straightened

state after coming off its pulley wheel, it means
that the chain links are "dead". This can be
caused by factors such as being poorly lubrica-
ted for a long time, abrasive corrosion, or over-
loading. You will need to replace the chain if the
"dead links" persist after cleaning and re-lubri-
cating the chain.
External wear 
Check the exterior side of the chain for wear.

The wear must not exceed 5% of the height of a
chain link. We recommend that wear be less
than or equal to 3% for serious instances or for
safety reasons.
Damage 
● Has the chain warped?

● Can you see small abrasions on the chain link
apertures?
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80 Lifting system
Chains
Broken chain links 
If cracks appear near the top of the chain links

or if some parts of the tops of the chain links are
missing, the chain link is said to be broken. This
fault is caused by overloading or fatigue. Corro-
sion is a factor contributing to this fatigue break-
age.
Running test
Running test
We recommend checking the oil on the surface
of the chain. Check for abnormal sounds or
signs of vibration while inspecting the chain as it
is running.
Lubrication
Regular leaf chains have pulling and lifting func-
tions. They are also known for their durability,
strength, and resistance to wear and fatigue.
These features make it necessary to carefully
maintain and lubricate leaf chains in order for
customers to get the best performance.
Lubrication intervals
The length of interval for re-applying lubrication
depends on different work and environmental
conditions. Uninterrupted maintenance and lubri-
cation can ensure that sufficient low viscosity oil
is present in the chain. You should immediately
clean the chain and re-apply lubricant if corro-
sive liquids come into contact with it.
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Lifting system 80
Chains

Relationships between different methods of lu-
brication and chain wear elongation are shown
in the image. The service life of chains with am-
ple lubrication is 60 times that of chains that op-
erate when dry.
● Operating when dry
● One-off lubrication
● Temporarily operating when dry (interval be-
tween re-lubrication has been to long)
● Insufficient lubrication
● Ample lubrication
Approximately 60% of faults with chains can be
attributed to insufficient lubrication. Thus, insuffi-
ciently lubricated chains can lead to: abrasive
corrosion, warping of the chain frame, pins mov-
ing, noisiness and pitting corrosion. These kinds
of outcomes easily occur when lubricating oil is
only applied to the outer part of a chain, without
getting into the linkages.
Replacing the chain

If a chain needs to be replaced due to wear
elongation, the above-mentioned malfunctions,
or damage, you must use good-quality products
that meet with forklift truck equipment safety re-
quirements.
If there are two chains that need to be paired,
you must replace both chains at the same time.
You must observe the following rules when re-
placing chains
● Using a hammer to manually carry out riveting
is unavoidable during maintenance. You must
wear protective goggles for safety, because
flying debris may cause injury.
● Try to use original chain parts as well as new
chain link joints and pins. New parts can guar-
antee a tight fit between pins and outer chain
links, thereby ensuring the chain is in original
quality.
● Before removing the chain (extracting the riv-
et pin), you should grind the exposed head of
the rivet pin until it is smooth to prevent it from
damaging the chain link apertures.
● To guarantee chain quality, you should en-
sure that there is no damage to the chain or
its components while carrying out mainte-
nance.
● There must be sufficient friction fit between
the pin and the outer chain linkage. Suitable
friction fit is an important factor in ensuring
the chain's fatigue strength.
● During assembly, you must ensure that there
is enough clearance between each piece of
chain linkage to guarantee responsiveness of
60068042311 EN - 07/2021 - 01 80-17

80 Lifting system
Chains
the connection between the linking rings and
the chain.
● There must be sufficient riveting along the
end of the chain pin to increase the chain's
safety and reliability.
● You must replace the coupling pin between
the chain and the linking rings whenever you
replace a chain. They are subject to fatigue
load from high impacts. These preventative
replacements can stop the chain from experi-
encing early fatigue failure and also prevent
accidents from occurring.
● As for conditions, a repaired segment of chain
must be able to pre-pull a load at 30% of its
minimum tensile strength to ensure that the
chain offers its original performance.
● Manufacturers cannot be held liable if chains
from different manufacturers are assembled
together during maintenance.
● You must not paint chains. Painting chains
prevents lubricating oils from penetrating the
chain and makes it more likely for the chain to
suffer from dry friction.
Summary
Leaf chains are important safety components in
forklift trucks. However, whether leaf chains offer
a long service life to users depends a great deal
on appropriate maintenance and lubrication.
These are maintenance operations that users
can carry out.
Chain adjustment 
During normal use, forklift truck chains loosen or

may become elongated due to users' differing
work conditions and habits. This can lead to
height differences between the two forks and to
stress on the chains on either side when lifting
goods. It is therefore necessary to regularly in-
spect and adjust chains to keep the chains on
both sides at the same tightness.
Procedure for adjusting the lift mast chains

 Check which chain is loose as you apply
pressure to the chain
 Unfasten the loose chain's adjustable prevail-
ing torque nut
 Adjust the prevailing torque nut to get both
chains to the same tightness
 Tighten the prevailing torque nut
80-18 60068042311 EN - 07/2021 - 01

Lifting system 80
Chains
Leaf chain maintenance and servicing

Replacement parts 
(1) Lower mid-lift mast main roller (2);

(2) Lock ring (2);
(3) Specific position on the lift mast.
Specific procedures
 Start the machine and remove the forks. 
Then, use the rear tilt operating lever to tilt the
lift mast backwards to its maximum angle.
60068042311 EN - 07/2021 - 01 80-19

80 Lifting system
Chains
 Operate the lifting joystick and raise the mid 
cylinder until the highest part of the load back-
rest is the same height as the inner mast.
Turn of the machine, switch off the key
switch, and activate the hand brake.
 Use straps to fix in place the load backrest 

(A), the inner mast (B), and upper crossmem-
ber of the lift mast middle (C). Position 1 must
be held in place by a crane.
 Remove retaining bolts 1, 2, 3, 4, 5, and 6 on 

the left and right cylinders. Retaining bolts 5
and 6 are at the bottom of the cylinder and
can only be removed with a 18# wrench.
80-20 60068042311 EN - 07/2021 - 01

Lifting system 80
Chains
 Raise the crane (or forklift truck) as well as 
the load backrest, upper crossmember of the
inner mast, and upper crossmember of the lift
mast middle. Separate the piston crowns of
the side cylinders from the fixing ports on the
lift mast middle.
 Rock the side cylinders left and right and re- 

move them. You should be able to remove
them when they separate from the side cylin-
der fixing port on the lift mast middle.
 The upper parts of the left and right side cylin- 

ders approach each other at mid-point in the
direction of the arrows shown in the diagram.
(The upper parts of the left and right side cyl-
inders will already be separated from the lift
mast middle when performing step 5).
60068042311 EN - 07/2021 - 01 80-21

80 Lifting system
Chains
 Lower the crane (or forklift truck) slowly. At 
this time, the load backrest (A), inner mast
(B), and lift mast middle (C) will lower under
the weight. Allow them to lower until you can
see the main rollers on the left and right sides
at the lower part of the lift mast middle.
 Remove the flexible circlip (A) using circlip pli- 

ers. Then, gently remove the main rollers. Ap-
ply lubricating grease to the new main rollers
and then install them. (The method is the
same for both the left and right side).
NOTE
You must install the outer flexible circlip (A) on

the left and right main rollers.
 Raise the crane (or forklift truck) until the lift 

mast middle slides into the outer mast. Place
the left and right side cylinders vertically and
tighten the mounting screws on the cylinder
bottoms.
80-22 60068042311 EN - 07/2021 - 01

Lifting system 80
Chains
 Slowly lower the crane (or forklift truck). This 
will cause upper cylinder heads(1)(2) on both
the left and right side cylinders to fit into the
lift mast middle's fixing ports. Tighten the bolts
and then fix in place the bolts at positions 3
and 4.
 Confirm that all fixing bolts are tight and then
operate the forklift truck's lifting and lowering
functions.
60068042311 EN - 07/2021 - 01 80-23

80 Lifting system
Chains
80-24 60068042311 EN - 07/2021 - 01

KION Baoli (Jiangsu) Forklift Co., Ltd.
Add: No. 8 Xinzhou Road,Economic Development Zone,
Jingjiang, 214500, Jiangsu, China
0086-523-80161860
export@baoli-mh.com
en.baoli-mh.com
60068042311-EN-07/2021 - 01-1

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Workshop literature

Diesel Forklift Truck

Format of training manual

Chapter Table of contents

The introduction to the training manual is fol-

monstrably proves their professional exper-

qualified person has gained practical experi-

out, such as based on the results of a hazard

60068042311 EN - 07/2021 - 01 III

Working on the electrical system

 Never wear rings, wrist watches, jewellery,

Clean the area surrounding the part in question

instructions when using lubricants and clean-

immediately with a suitable absorbent, and

cants as specified. Follow laws and regula-

ters etc. as per local legislative requirements

10 Internal combustion engine

60068042311 EN - 07/2021 - 01 VII

Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-85

VIII 60068042311 EN - 07/2021 - 01

Crankshaft pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-219

Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-234

Cooling system engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-235

Particle filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-236

20 Running gear and drive train

Removing the clutch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21

Drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-36

Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-42

Precautions for steering device installation and usage . . . . . . . . . . . . . . . . . . . . . . . . 20-47

Brake system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-55

30 Chassis and bodywork

Design and labbeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-3

Display-operating unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-3

Operating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-4

Electrical system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-9

Starter batteries and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-26

XII 60068042311 EN - 07/2021 - 01

Punp-motor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-2

Directional control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-7

Cylinder leak inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-42

Flow control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-44

60068042311 EN - 07/2021 - 01 XIII

XIV 60068042311 EN - 07/2021 - 01

Industrial truck documentation

60068042311 EN - 07/2021 - 01 00-1

00-2 60068042311 EN - 07/2021 - 01

Data sheet for KBD25

This VDI data sheet specifies only the technical

60068042311 EN - 07/2021 - 01 00-3

Turning Radius Wa (mm) 2440

00-4 60068042311 EN - 07/2021 - 01

Data sheet for KBD30

60068042311 EN - 07/2021 - 01 00-5

Drawbar Pull Tractive Effort (at 2km/h) with/without load KN 19/16

00-6 60068042311 EN - 07/2021 - 01

Data sheet for KBD35

60068042311 EN - 07/2021 - 01 00-7

Drawbar Pull Tractive Effort (at 2km/h) with/without load KN 19/16

00-8 60068042311 EN - 07/2021 - 01

60068042311 EN - 07/2021 - 01 00-9

Consumables and cleaning agents used during

ance with the manufacturer's instructions.

store lubricants, and store them in approved

from hot objects and open flames.