Technical understanding of

2.0~3.5D-7SA Diesel FL

HCE Training Center

20FZG12
11
Contents
Ⅰ. Model features
Ⅱ. Diesel Engine
Ⅲ. Power Train System
Ⅳ. Electric System
Ⅴ. Hydraulic System

2
1. 7SA Model Line-up
Wide view
MAST

LED - Front/Rear
LIGHT

Stamping
Overhead guard

Stamping iron
Hood
20L-7SA
25L-7SA
2.0-3.5T LPG FORKLIFT
30L-7SA
35L-7SA
CONTER BALANCE
FORKLIFT

2.0-3.5T 20D-7SA
DIESEL 25D-7SA
FORKLIFT 30D-7SA
35D-7SA

3
1-1. Specification (DIESEL)2.0 ~ 3.5 Ton
30D-7SA FDZN30 FD30T3CZ
Item
(Hyundai) (Toyota) (Unicarriers)
Manufacturer Mitsubishi Toyota Isuzu
Model S4S-455 1DZ-Ⅱ C240
Type Mechanical Mechanical Mechanical
Engine Rated Power (ps/rpm) 48/2,250 47/2,200 48.1/2,500
Emission Tier III (EC) Tier II (Unknown) Tier III (EC)
MAX. Torque (kg-m/rpm) 18.0/1,700 - 14.3/1,800
Displacement (cc) 3,331 2,486 2,369
Manufacturer Zhongchai Aisin -
Shift Type Power Shift (1/1) Power Shift (1/1) Power Shift (1/1)
T/M Number of Speed (F/R) 1/1 1/1 1/1
&
Axle Connection Type Transaxle Separate Separate
Brake Type Drum Drum Drum
Parking Brake Type Toggle Toggle Toggle
Manufacturer Shimatsu Kayaba Shimatsu
Pump
Power Take Off Engine Engine Engine
Manufacturer Hea Hong Nishina Shimatsu
MCV
STD 2-Spool 2-Spool 2-Spool

4
1-2. Dimensions

30D-7SA FDZN30 FD30T3CZ

Model
(Hyundai) (Toyota) (Unicarriers)
Load Capacity kg 3,000 3,000 3,000
Load Center mm 500 500 500
Power Type - Diesel Diesel Diesel
Service Weight kg 4,380 4,225 4,240
Max. Fork Height (STD) mm 3,000 3,000 3,000
Wheel Base mm 1,700 1,700 1,700
O.H.G Height mm 2,170 2,195 2,150
Overall Length mm 3,775 4,025 3,775
Overall width mm 1,210 1,255 1,225
Travel speed (unloaded) km/h 19.0 15.0 19.5
Lifting speed (Loaded/Unloaded) m/s 0.43/0.44 0.40/0.42 0.45/0.47
Lowering speed (Loaded/Unloaded) m/s 0.45/0.4 0.50/0.50 0.45/0.45
Max. drawbar pull (Loaded) N 19,000 17,800 13,700
Gradeability (Loaded) % 20 23 18
Outside Turning Radius mm 2,430 2,400 2,370

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1-3. Comfortable Operator compartments

210→260m
m

330→280mm

- Enough floor space for pedals and entrance.

- Small sized Steering Wheel.

Adjustable steering wheel

: 25° of tilting angle offers accommodation
for various operator’s conditions.

- Front & Rear LED Lamp (STD)

6
1-4. Technical Features

1) OPSS (Operator Presence Sensing System, Option)

- Travel cut-off and Parking warning
- Mast and Tilt lock

2) Electrical Seatbelt Interlock (Grammer Seat, Option)

: Parking brake-On or No seatbelt interlock.
- Travel electric power cutoff

Grammer Seat(Option)
1) Armrest + OPSS s/w
2) Armrest + OPSS s/w + Buckle s/w
3) Reliable Monitoring

⑤
④’ ④
① Hour meter ⑤ Warning & Indication lamps
② ③ ② Fuel gauge - Neutral light
- Sediment indication light
① ③ Water temp. gauge - Pre-heat indication light
④,④’ Turn indicator - Seat belt light
- T/M oil temp. light
- E/G oil pressure alert light
- Battery charge light
- Air filter indication light

7
Diesel Engine

8
2. MITSUBISHI S4S-455 (EU : Stage-3)
s 4 s -

Alternator

Start Motor PTO for Hyd. Pump

9
2-1. Fuel system

Air inlet

Fuel inlet

Fuel filter
(Fuel-Water separator)

Fuel leak

Stop
solenoid

Coolant inlet

Fuel injection
pump

1) Caution for maintenance and service work

(1) Each engine has the minimum no-load(low idle speed) and maximum no-load speed checked on the test bench
at the factory and has the setting bolts sealed. These settings can be inspected and adjusted at the designated
service shop only.
(2) Whether the seals are intact or not has important bearing on the validity of claims under warranty.
Be sure to seal all of the specified sections.
(3) When inspection and adjusting the governor, before to start the engine, be sure the lever is not at the position of
extremely high speed.

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2) Adjustment of Min/Max no-load speed

: Prior to adjust the governor, warm-up the engine long enough for the water or oil temperatures to rise to 70℃.
(1) Setting low idle speed
▶ Locate the speed control lever to touch the idle speed adjusting screw, and turn the screw.
(2) Setting maximum speed
▶ Hold the speed control lever in the specified maximum speed position → Adjust the maximum speed adjusting
screw to the specified speed.

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2-2. Lubrication system

Idler gear

Camshaft gear

Fuel injection
pump gear
Crankshaft gear
(3~4 bar)

Oil Pump

Oil Pump

Inner rotor

Outer rotor

12
2-3. Cooling system

1) In cooled water temperature(lower than 76℃)

: Thermostat shuts off the passage between circulating water and
radiator.
- The cooled water will be circulating in water sleeve and water pump
through the secondary valve (Minor circulation) to make sure the
engine warms up quickly.

2) In Hot water temperature(higher than 76℃)

: The thermostat will open the passage to the radiator.
- Water flows from the top of radiator to bottom through radiator core.
Thermostat
- During the fan blows, fan blowing air takes the heat away.

Water pump

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2-4. Air intake system

Double Air filter

Piston

- Rated air flow of the air filter

: 240m3/h.

- Be sure to face the dust outlet

downwards while installing.

(Rough air filter)

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2-5. Diesel Engine maneuvering
❶ Use only specified fuel (&MHI Genuine fuel filter) ,engine oil (&MHI Genuine oil filter) listed in the OM manual.
❷ Wear proper work clothes and protective gears.
❸ Never Break the Seals.
: To ensure the proper engine operation, the fuel injection pump, governor, cylinders and fuel control link are
provided with seals.
(If the engine is operated with the seal tampered, no guarantee will be provided.)
❹ Manner of engine break-in
: To break in a new engine, operate the engine at a speed lower than the rated speed under light load during
the first 50 hours of operation.
（Please change immediately engine oil and oil filter after the first 50 hours.）
Break-in operate
Rotational speed（rpm） Load(PS) Time(min)
1 Low speed 600~900 No-load 20
2 Medium speed 1000~1200 No-load 10
3 High speed 1400~rated No-load 10
4 25% 20
5 50% 20
Rated speed
6 75% 30
7 100% 20
❺ Engine warming up
- After starting the engine, run it at a low idle speed for warming-up.
- Start the work after the coolant temperature is raised sufficiently.
- Don’t continue the warm-up operate for a long time.
Long warm-up operation causes carbon deposits in the cylinders, and may lead to incomplete combustion.

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❻ Cool down the engine before stopping.
Cool down the engine at a low idling for five to six minutes before stopping it.
(The turbocharged engine must perform this operation)

❼ Never operate engine under overload condition.

If the engine shows an overload condition such as back exhaust smoke, reduce the load
immediately and operate the engine at appropriate output and load.

❽ Prohibition of continuous low-load operation.

Low load continuous opration(less than 30%)must be limited within one hour after a continuous
low load operation, run the engine at a load of 50% or higher for 30 minutes or more to prevent
carbon accumulating.

❾ Do not operate starter for continuously.

Do not use the starter for more than 10 seconds at a time.
If the engine doesn’t start, wait for at least 30 seconds before cranking again.

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Power Train System

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1. Electro-Hydraulic TRANSMISSION
1-1. Specification

Oil Feed pump Torque

Converter
Hydraulic Clutch

※ T/M oil : 9ℓ, ATF DEXRON Ⅲ

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1-2. Torque Converter

1) Pump impeller turns along with the rotation of Engine.

- Charging pump’s driving gear is linked with Pump impeller.

2) Guide pulley(Stator) changes Oil flowing direction

to flow back to the Pump impeller.

3) Turbine is connected with the turbine shaft.

- Input shaft of clutch is linked with turbine shaft. (T/M Oil feed Pump)

4) One-way over running clutch

(Stator)

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1-3. Composition – Inner section of Transmission
Electric Control Safety
valve(FWD/REV) (Overflow
valve)
Electric Control Clutch Clutch
valve(FWD/REV) -FWD -REV

Inching
valve

Oil(Charging) Control
Pump valve
Assy

Output
Shaft
Gear-
Output

Gear-
Idle

- Turbine → Input shaft → Clutch → FWD/REV / Idle gear(acting in Reverse) → Output Shaft
- T/M oil : ATF DEXRON Ⅲ, 9ℓ

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 1-4. Clutch – FWD/REV
Clutch-FWD/REV

FWD REV

Gear-Idle
Oil Fill pipe Idle Shaft

Connected with
Torque Converter →

Gear-Output

Output Shaft

Tor-Con Assy

Charging pump

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1-5. T/M oil circuit

Electric Control Oil filter

valve(FWD/REV)

Overflow
(Safety) valve

Oil cooler
Cushion Main relief(Major
valve pressure adjusting)
valve

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1-6. T/M oil ports

Electric Control valve(FWD/REV)

- Solenoid(5~6Ω)

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2. DRIVE AXLE
Internal Combustion Forklift

2-1. Differential

Spline
shaft Spiral Bevel
gear

Planet Gear

go Straight Cross shaft

Gear Ring

Diff Housing-Rh

Turning-CW

( Differential)
Axle gear
※ Gear oil : 4ℓ, MOBILE FLUID 424 Diff Housing-Lh

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2-2. Composition of Drive Axle

- Drive
Internal axel is mainly
Combustion composed of axle housing,
Forklift
wheel hub, half shaft, and Drum brake assy.

- The power is transmitted to half shaft through

speed differential, and finally the front wheel is
actuated by wheel hub for rotation.

- Each wheel hub is mounted on axle housing

through two tapered roller bearings, so the half shaft
only bears the torque transmitted by wheel hub.
Drum Brake Assy
- Oil seal is fitted inside the wheel hub to prevent entry
of water and dust or oil leak.

Note] 1. Wheel Rim

2. Wheel Hub
3. Brake Cylinder
4. Axle Housing
5. Half Shaft

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3. Brake system
3-1. Service brake
- The service brake system is composed of Brake pedal,
Main brake cylinder, Brake wheel cylinder, Brake shoe
and Drum.

- When Brake pedal is pushed, the brake oil in the main

brake cylinder flows to the Brake wheel cylinder.

- Thus the piston in the Brake wheel cylinder is forced to

activate the brake shoe plate to firmly compress the brake
drum to achieve the effect of deceleration or brake.

※ Drum type brake - Reference only

1. Brake pedal
5
2. Brake master cylinder
Parking brake 3. Brake oil pipe
lever
4. Brake shoe
4 5. Brake wheel cylinder

Brake switch(for tail brake lamp)

Parking brake
Brake adjuster
cable

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3-2. Mechanical Parking brake

3-3. Automatic Clearance regulator Park’g brake cable

Service brake oil inlet
Cylinder piston
& Piston rod
Brake plate(Drum)
3-4. Inspection of Wheel brake
1) Clearance between Brake drum and Brake shoe :
0.4~0.5mm(0.25~0.4mm for 3.0/3.5 Ton FL)
1. Brake Wheel cylinder
2) Clearance between Wheel cylinder body
and Piston : 0.065mm~0.150mm(2.0~3.5 Ton FL)
3) Thickness of brake shoe :
7.2mm(8.0mm for 3.0/3.5 Ton FL)
- Minimum thickness :
2.0mm(1.0mm for 3.0/3.5 Ton FL)

Adjusting Rod

2. Park’g brake
lever

3. Adjuster
4. Brake shoe Ass’y

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3-5. Adjustment, Brake pedal & Inching pedal

※ Brake oil : DOT-3, 0.5ℓ

Adjust Bolt for Brake pedal

(Floor plate)

Brake pedal

Adjust Bolt for Inching pedal

- Pedal adjustment standards

2.0 ~ 3.5 Ton

Brake Idle stroke 55~60 mm
pedal Pedal height 111 mm(LPG: 113 mm)

Inching Idle stroke 30~40 mm (Adjustment - Brake pedal)

pedal Pedal height 111 mm(LPG: 113 mm)

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3-6. Troubleshooting Guide – Brake system

Problem Cause of problem Remedy

1. Clearance of brake shoe not properly adjusted - Adjuster to be adjusted

2. Wheel brake is too hot - Check whether or not
3. Oil leak with brake system skidding exists.
Poor braking 4. Contact between brake drum and brake shoe
5. Impurity is stuck on the brake shoe To be replaced, repaired
6. Impurity blended into brake fluid or adjusted.
7. Brake pedal improperly adjusted

1. Surface of brake shoe hardened or impurity is stuck on it

Noise with 2. Bottom plate distorted or bolt loosened To be replaced or
braking 3. Brake shoe distorted or installation incorrect repaired
4. Brake shoe worn
5. Bearing of wheel loosened

1. Oil stain on surface of brake shoe

Lack of uniformity 2. Wheel cylinder out of operation To be replaced, repaired
braking 3. Brake shoe return spring is damaged or adjusted.
4. Brake drum deflected

1. Clearance of brake shoe not properly adjusted - Adjuster to be adjusted

2. Air blended into brake oil - Air to be bled
Weak braking
3. Oil leak with brake system To be replaced or
4. Brake pedal improperly adjusted repaired

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4. Steering System
4-1. Specification
Steering wheel
Rear Wheel
Type of Steering System
Steering

Cycloid Full Hydraulic Steering Gear BZZ7-125

Cylinder diameter(mm) Φ70

Steering
Cylinder Diameter of piston rod (mm) Φ50

Stroke (mm) 198

Diameter of steering wheel (mm) Φ300 Direction

column

Steering Gear
(Diverter)

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4-2. Composition of Steering Axle

- Steering axle is composed of steering axle

body, steering cylinder, link/knuckle assy
and steering wheel hub.

Steering Axle body - Slider-crank mechanism is applied to

steering trapezium.

- The steering knuckle is actuated by cylinder

piston rod through link rod for rotation to
make steering wheel deflect, thus to
achieve steering.
Knuckle assy

Wheel Hub

Steering cylinder

Link assy

31
Electric System

32
1. Electric components

Double-sided yellow
square light

Front headlight
(LED)

Rear headlight
(LED)

Beacon light

Cluster

Key S/W 3-color tail light

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 Battery
(6-QW-90, 90Ah)
Electric
horn

Electric Reverse
(Fuse) box buzzer
Light control

Multi-function Lever
(Gear control lever) (Turning control lever)

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 2. Electric Circuit
1) Electric circuit -Diagram

FU8

Main
RY FU4
FU2 FU3 FU5 FU6 FU7
Fusible
link
Fuse Box

Flasher
Key unit Cabin
S/W
Cluster
Direction Brake
Start pressure Tail-Light Head-Light
Lever
RY Neutral S/W S/W S/W
Turning
RY S/W

Alternator Preheat
RY Fuel
Preheat Water shut-off
Timer Temp. sol. Horn
S/W

Fuel Air-Con Wiper

Air filter T/M-Sol. v/v
Battery E/G oil Blower CAB
level
(12V) press. light
Start Sediment
E/G
motor
Preheater

35
1) Fuse Box
- Fuses : Protecting the circuits to prevent
electrical appliances and wire
being burnt due to short circuit. K1 K2 K3 K4 K5

- Relays : Making the small capacity switch F1 F8

can control high-power electric
appliances.
K6 K7 K8
(Relay array)

(Connectors)

(Fuse array)
1.MAIN POWER 9.DIRECTION POWER 17.GROUND
2.PRE-HEAT POWER 10.HORN POWER 18.FLASHER POWER
3.START POWER 11.LIGHT POWER 19.NONE
4.LAMP POWER(FRONT) 12.KEY-SWITCH POWER 20.CAUTION LIGHT POWER
5.LAMP SWITCH(FRONT) 13.NONE 21.SAFE START
6.LAMP POWER(BACK) 14.GAUGE POWER 22.NONE
7.LAMP SWITCH(BACK) 15.ENGINE POWER 23.START RELAY
8.CAB POWER 16.PRE-HEAT WARNING 24.MAIN RELAY

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 3. Electric functions
1) Power supplying circuit

FU8

Main
RY FU4
FU2 FU3 FU5 FU6 FU7
Fusible
link
Fuse Box

Flasher
Key unit
S/W
Cluster
Start Direction
RY Lever
Neutral Turning
RY S/W

Alternator Preheat
RY Fuel
Preheat
shut-off
Timer
sol.

Battery
E/G
Start Preheater
motor

☞ B+, Stand-by : Battery(+) → Fusible link → Alternator(B+)/Start RY(Contact point)/Preheat RY(Contact point)

Fuse Box(FU1) → Key S/W(B+)

37
 2) Ignition circuit

FU8

Main
RY FU4
FU2 FU3 FU5 FU6 FU7
Fusible
link
Fuse Box
Key
S/W Flasher
unit
IG
Cluster
Start Direction
RY Lever
Neutral
RY

Alternator Preheat
RY Fuel
Preheat shut-off
Timer sol. Neutral
S/W

‘N’ -
Battery Indication
E/G
Start Preheater
motor

☞ Key S/W-’IG’ → ① Main RY(On) / Preheat Timer&Preheat RY(+, Stand-by)

Fuses(FU2~FU7) → Cluster(On)
② Preheat Timer(On) → Preheat RY(On, 10sec) → Preheater(On) ③ Fuel shut-off solenoid → On

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 3) E/G Start circuit

Fusible
link

ST Flasher
Key unit
S/W
Cluster
Start Direction
RY Lever Neutral
RY

Alternator Preheat
RY
Preheat
Timer

Neutral
Battery
E/G S/W
Start Preheater
motor

☞ Key S/W-’ST’ → Start RY(On), only if the Neutral RY is ON condition[Direction lever-‘Neutral’] → Start motor(Running)

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3-1) Start Motor
(1) Specification : 12V, 2.2Kw

Magnet Switch Ass’y

Lever

Armature
Start Motor

Magnet Switch

Pinion

Over running clutch

Armature

Pinion
Brush & Holder Ass’y

40
(2) Working Principal of Start Motor
- B+ power is supplied by the Battery
- Key ‘ST’ → Start RY ‘On’ → Electric Power is supplying to M port of Start Motor
- Lever moves to engage the pinion with Ring-gear → Engine starts running

Magnet Switch

B+
Battery
Start RY
M

Lever
Brush Ass’y & Yoke
Armature

Pinion & Over running

clutch

41
3-2) Generator
- Specification : 12V, 50A

(1) Basic structure

42
(2) Working principle of Generator

▶ Key ‘On’ : Battery(+) → (Cluster)charging indicator →

regulator → Rotor coil → GND
- Generation voltage ＜ Battery(+) voltage
- Charge warning ‘On’.

▶ Key ’Start’ : Generation voltage ＞ Battery(+) voltage

- Charge warning lamp ‘Off’.

43
 4) Cluster - Indication / Warning circuit

Fusible
link

Flasher
Key unit
S/W
Cluster
Start Direction
RY Lever
Neutral
RY

Alternator

Preheat Water
Timer Temp.

Turn- Turn-
Air filter Fuel Neutral
Battery E/G oil LH RH
E/G level
Start Preheater press.
Sediment
motor

- Gauges : Hour-meter / Fuel / Water temperature

- Warning & Indication lamps : Battery charge / Preheat / Eng. oil pressure / Sediment / Air filter / Neutral / Turn-LH,RH
and TM oil temp.(not drawn)

44
(1) Cluster
Hour-meter
Battery Charge
Seat belt Light
Air filter
T/M Oil Temperature
E/G Oil Pressure
Sediment indicator light
Neutral light
Right turn indicator light
Left turn indicator light
Water temperature gauge

Fuel gauge

45
(2) Fuel quantity sensor

Fuel position Resistance(Ω)

FULL 180±5

1/2 95±5

EMPTY 10±3

46
 5) Valve block control circuit

Fusible
link

Flasher
Key unit
S/W
Cluster
Start Direction
RY Lever

FWD REV

Alternator

Preheat
Timer

T/M-Sol. v/v
Battery
E/G
Start Preheater
motor

- Drive direction control : ① Direction lever-FWD → T/M-FWD solenoid(On)

② Direction lever-REV → REV solenoid(On)/Backup light(On)/Backup alarm(On)

47
 6) Lighting and Sound circuit

Fusible
link

Flasher
Key unit
S/W
Cluster
Brake
Start Direction Tail-Light Head-Light
pressure
RY S/W Neutral S/W S/W
S/W Turning
RY S/W

Alternator

Preheat
Timer Horn
S/W

Battery
E/G
Start Preheater
motor

- Brake pressure S/W → Brake light(On/Off) / Horn S/W → Horning / Illumination-Light S/W → Tail light(Head light)

48
 7) Cabin electric circuit

Fusible
link

Flasher
Key unit Cabin
S/W
Cluster
Start Direction
RY S/W Neutral
RY

Alternator

Preheat
Timer

Air-Con Wiper
Battery Blower CAB
E/G
light
Start Preheater
motor

- Air conditioner / Blower / Wiper / CAB light

49
Hydraulic System

50
1. Hydraulic circuit
1) Major components
(Brake Pedal)

Steering valve Multi-way valve

(Alternator)

Hyd. Oil Pump

51
2) Flow control
- Steering function has priority
(LS : Load Sensing)

- Main relief valve setting : 175 bar

Shut off
valve
- By-pass valve regulates steering
Flow TILT spool pressure --- 100 bar
regulator

- In neutral position, only a small volume

LIFT spool
of oil in the steering system returns to
the tank → Energy saving.
Bypass
safety v/v
Bypass v/v - Down speed control by a Flow regulator
Main safety (Drive Axle)
v/v

Flow regulator

52
2. Hydraulic oil pump
1) Specification of Gear pump

Driving gear

Driven gear

- Specification
Theoretical Rated Max. Min. Max.
Pump model displacement pressure pressure speed speed Remark
ml/r MPa MPa r/min r/min

SGP1A28.2D2H
30D-7SA 28.2 20.6 24.5 400 3500
1-L707D
- Rotation :
CCW
SGP1A28.2D2H
25L-7SA 28.2 20.6 24.5 400 3500
9-R330C

53
3. Main Control Valve

1) Tilt locking
(Tilting)
Tilt-FWD

Tilt lock v/v

54
2) Balance spool valve(L)

Hyd. work PS Q

Balance valve

LS →

(Steering) PS

- 175bar
(Relief-Steering)
- 100bar

55
4. Steering gear
1) Load sensing

T
LS Port
P

( BZZ7-125, Displacement: 125ml/r )

- Hydraulic Power Steering system

56
5. Lift Cylinder
1) Safety function

Shut-off V/V

Oil hole

Shut-off V/V Shut-off V/V

Orifice

( Normal condition ) ( Emergency condition )

57
6. Planned Maintenance
- Fuel and Lubricants

Note] 1. Oil types

: Lubricant : Engine oil △ : Brake oil
: Wheel bearing lubricant : Gear oil
▽: Tor-con oil ◇ : Operating tank oil
○: Water

2. , □ : Add, ◎, : Exchange

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Thanks for being with HCE.

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