the best service repair manual

1. SERVICE MANUAL
RATED CAPACITY : 5000~7500kg
SF50-75SD/L
CMP50-75sD/L
#40–1, Ungnam-Dong,
Changwon-City,Kyungnam,
Korea
Part No. 8034927
Manual No. SM690
Manufactured by
Jun,2004
Rev.2

2. 1
FOREWORD
G E N E R A L
00
02
FOREWORD
This shop manual has been prepared as an aid to improve quality of repairs by giving the
serviceman an accurate understanding of the product and by illustrating the correct way to
perform repairs and make judgements. Make sure you understand the contents of this manual
and use it to the full effect at every opportunity.
This shop manual mainly contains the technical information necessary for operations performed
in a service workshop.
For ease of understanding, the manual is divided into sections for each main system of the
machine, and the sections are further divided into groups.
HOW TO READ THIS MANUAL
CHAPTER AND SECTION
This manual is issued as a guide to carrying out repair and maintenance. To easily understand
this manual it is divided as follows :
Example) 10 – 01
Section number (01 : Structure and function)
Chapter number (10 : Engine)
• Improper operation and maintenance of this machine could result in serious injury or death.
• Read the Operation and Maintenance Manual carefully BEFORE operating the machine.
• Always keep the Operation and Maintenance Manual and Parts catalogue near the work
area.
• Obey precautions concerning flammable liquids, hazardous fluids, oils, lubricants and
cleaning solvents.
• To prevent injury to workers, this symbol is used to mark safety precautions in this
manual. The precautions accompanying this symbol should always be followed carefully.
• The specifications contained in this shop manual are subject to change at any time and
without any advance notice. Contact your SAMSUNG distributor for the latest information.
SAFETY

3. 2
FOREWORD
G E N E R A L
00
02
PAGE
Page numbering is started from each section. Therefore, revised pages can be easily inserted.
Also, additional pages and revision number can be indicated.
Ex) 15 – 1
3rd revision
Additional page from page 15
15th page of the section
For the revision status in this manual, refer to REVISION HISTORY.
SYMBOLS
The following symbols as defined below are used in this manual to convey the intent of the
instructions concerning safety and repair.
Symbol Item Remarks
Safety
Caution
Tightening
torque
Tool
Adhesive
Lubricating
Special safety precautions are necessary when
performing the work.
Special technical precautions or other precautions for
preserving standards are necessary when performing
the work.
Places that require special attention for the tightening
torque during assembly.
Places that require proper tools used in assembling
and disassembling.
Places to be applied with adhesive.
Places where oil or lubricant must be added.

4. 1
SAFETY
G E N E R A L
00
03
GENERAL PRECAUTIONS
SAFETY PRECAUTIONS
• When carrying out any operation or maintenance, have trained and experienced personnel carry
out the work.
• When carrying out any operation or maintenance, carefully read the Operation and Maintenance
Manual.
Read all the precautions given on the decals which are fixed to the machine.
SAFETY DEVICE
• Make sure that all guards and covers are mounted in their proper position. Repair or replace
if damaged.
• Pay attention to the method of using any safety locking device or safety belt.
SAFETY CLOTHES AND HELMET
• Wear the specified work clothes in the correct manner.
• Use the specified protective gear (helmet, safety glasses, safety shoes, mask, gloves).
Guard against injury from flying pieces of metal
or debris, wear goggles, gloves and helmet.
Always have a trained and experienced welder
carry out any welding work.
When carrying out welding work, always wear
welding gloves, apron, glasses, cap and other
clothes suitable for welding work.

5. 2
SAFETY
G E N E R A L
00
03
PREPARE FOR EMERGENCIES
• Know where fire extinguishers are located and
how to use them.
• Keep a first aid kit and an eye wash kit near
the work area.
• Keep emergency numbers for doctors, ambul-
ance service, hospital, and fire department near
your telephone.
HANDLE FLUIDS SAFELY–AVOID FIRES
• Handle fuel with care it is highly flammable.
• Do not refuel the machine while smoking or
when near open flame or sparks.
Always stop the engine before refueling
machine. Fill the fuel tank outdoors.
• Store flammable fluids away from fire hazards.
Do not incinerate or puncture pressurized
containers.
DISPOSE OF FLUIDS PROPERLY
• Improperly disposing of fluids can harm the
environment and ecology. Before draining any
fluids, find out the proper way to dispose of
waste from your local environmental agency.
• Catch draining fuel, oil, or other fluids in
suitable containers. Do not use food or
beverage containers that may mislead someone
into drinking from them. Wipe up spills at once.
• Do not pour oil into the ground, down a drain,
or into a stream, pond, or lake. Observe
relevant environmental protection regulations
when disposing of oil, fuel, coolant, brake fluid,
filters, batteries, and other harmful waste.
EX028
EX043

6. 3
SAFETY
G E N E R A L
00
03
AVOID HARMFUL ASBESTOS DUST
• Avoid breathing dust that may be generated
when handling components containing asbestos
fibers. Inhaled asbestos fibers may cause lung
cancer.
EX025

7. 4
SAFETY
G E N E R A L
00
03
PREPARATIONS FOR WORK
WARN OTHERS OF SERVICE WORK
• Unexpected machine movement can cause
serious injury.
• Before performing any work on the machine,
attach a “Do Not Operate” tag to the steering
wheel or the right control lever.
• When carrying out any operation with two or
more workers, always agree on the operating
procedure before starting.
USE TOOLS PROPERLY
• Use a tool only for its designed application.
• Keep all tools in good condition and know the
correct way to use them.
• Decide on a place in the repair workshop to
keep tools and removed parts.
• Always keep the work area clean and make
sure that there is no dirt or oil on the floor.
• Before adding oil or making any repairs, park
the machine on hard, level ground and put
blocks under the wheels to prevent the
mahcine from moving.
• Before starting work, lower the forks or any
other work equipment to the ground.
• Turn the engine OFF, remove the start key,
and apply the parking brake.
• Illuminate your work area adequately but safely.
Use a portable safety light for working inside
or under the machine. Make sure the bulb is
enclosed by a wire cage. The hot filament of
an accidentally broken bulb can ignite spilled
fuel or oil.
EX033
FX1008
EX042

8. 5
SAFETY
G E N E R A L
00
03
USE HANDHOLDS AND STEPS
• Do not jump onto or down from the fork lift.
• When getting on or off the fork lift, use the
step provided.
• Do not grasp an operating lever or steering
wheel when getting on or off.
• Always keep the step clean and repaired.
• Never operate with wet or oily hands and feet.
OPERATE FROM THE OPERATOR’S SEAT
• Do not operate the fork lift from any place
other than the designated operator’s position.
• Improper seating may cause serious injury.
FX019
FX020

9. 1
GENERAL
S P E C I F I C A T I O N S
01
01
LOCATION OF COMPONENTS
1. Mast
2. Lift cylinder
3. Control lever (Tilt, Lift)
4. Carriage
5. Forks
6. Overhead guard
7. Steering wheel
8. Driver’s seat
9. Engine hood
10. Counterweight
11. Steering tire
12. Tilt cylinder
13. Driving wheel
14. Frame
15. Steering axle
16. Driving axle
17. Rear hood
18. LPG tank (LPG only)

10. 1
GENERAL INFORMATION
P O W E R T R A I N
20
01
GENERAL INFORMATION
This section describes the method of detaching the transmisson from the vehicle, and the
diassembling, assembling, and overhauling of it.
CAUTION
Cleanliness is of extreme importance in the servicing, repair and overhaul of the
transmission. Before attempting any repairs thoroughly clean the exterior housing to
prevent the possibility of dirt entering the unit. Always conduct repairs in a clean,
dust free environment.
GENERAL
FEATURES
The torque delivered by the engine is multiplied by the torque converter and powershift
transmission to a maximum of 2.00 times, and is transmitted via the drive shaft to the axle
differential, axle shaft, final drives and driving wheels.
OPERATION PRINCIPLE AND FUNCTION
Engine →
→ → → →
→ →
Differential Axle shaft Final drive Driving wheel
Torque converter Transmission Drive shaft

11. 2
GENERAL INFORMATION
P O W E R T R A I N
20
01
• The torque converter is a type of hydraulic coupling that consists of an impeller connected to
the engine crankshaft, a turbine connected to the converter output shaft, and a stator which
redirects the oil from the turbine for recirculation into the impeller. As the load increases slippage
will occur between the impeller and turbine, so the rotational speed of the turbine will approach
O rpm (stall).
Therefore as the output shaft is decreasing in speed the torque multiplication will increase to
a maximum of 2.0 times when the output shaft is at O rpm.
• The electric shift control unit located on the steering wheel column energizes the selected
solenoid valves thus directing pressurized oil to the directional and range (gear) clutches. The
range and directional clutches direct the power flow through the gear train to provide the desired
speed range and direction. The reduction ratio for the range clutches are : 5.02–1st, 2.56–2nd,
and 1.00–3rd.
• The differential gear assembly consists of the pinion/bevel ring gear set and the differential
gear set. Power delivered from the transmission is reduced by the pinion/ring gear set and
then transmitted to the left/right axle shafts by the differential gear set.
• The final reduction of the power transmitted to the axle shafts occurs in the planetary unit of
each axle hub.

12. 1
TRANSMISSION
P O W E R T R A I N
20
02
TRANSMISSION
DISASSEMBLY
• Remove drive plate attaching capscrews and
washers. Remove drive plate and backing ring.
• Remove torque converter plug retainer ring.
• Remove plug and O–ring.
• Remove torque converter to turbine shaft
retainer ring.

13. 2
TRANSMISSION
P O W E R T R A I N
20
02
• Remove torque converter assembly.
• Remove torque converter to shaft locating ring.
• Remove filter assembly.
• Remove pressure regulator and regulator
sleeve.
Special tool can be fabricated.

14. 3
TRANSMISSION
P O W E R T R A I N
20
02
• Remove charging pump permanent pump hole
cover. (Not used when auxiliay pump is used.)
• Remove pump mounting capscrews and
washers. Remove pump and gasket.
• Remove converter housing to transmission case
capscrews and washers.
• Remove converter housing and gasket.

15. 4
TRANSMISSION
P O W E R T R A I N
20
02
• Remove impeller hub gear.
• Remove solenoid valve cartridge retainer nut
and O–ring.
• Remove solenoid coil and O–ring.
• Loosen solenoid valve cartridge.

16. 5
TRANSMISSION
P O W E R T R A I N
20
02
• Remove valve. Repeat procedures for
remaining solenoid valves.
• Remove bore plug and O–rings. This plug is
used in the middle bore position in the 3 speed
version only.
• Remove spacer plate capscrews and washers.
• Pry spacer plate away from transmission case
at dowel pin holes. Remove spacer plate and
gasket. Note aligning studs to facilitate spacer
removal.

17. 6
TRANSMISSION
P O W E R T R A I N
20
02
• Remove 1st and 2nd clutch assembly.
• Remove forward and reverse clutch assembly.
• Remove 3rd clutch assembly.
• Remove 3rd speed clutch shaft pilot bearing.

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19. 7
TRANSMISSION
P O W E R T R A I N
20
02
• Remove oil baffle capscrew and washer.
• Remove oil baffle.
• Remove oil supply tube O–ring.
• Remove supply tube and screen assembly.

20. 8
TRANSMISSION
P O W E R T R A I N
20
02
• Remove 3rd clutch gear and output shaft.
• Remove 1st and 2nd clutch shaft rear roller
bearing. Remove 3rd gear roller bearing.
• Remove roller bearing locating ring.
• Remove inner case set screw plug. Remove
clutch shaft distributor sleeve set screw.

21. 9
TRANSMISSION
P O W E R T R A I N
20
02
• Use a hammer puller (or any suitable puller) as
shown to remove distributor sleeve and shaft
pilot bearing.
• Pilot bearing and distributor sleeve removed.
• Remove modulator housing sleeve and O–ring.
• Remove inner, middle, and outer valve springs
and valve stop pin.