Hyundai 30DT-7 Operation Manual
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Hyundai 30DT-7 Operation Manual

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Group 1 Safety hints -------------------------------------------------------------------------------------------------------- 1-1
Group 2 Specifications ---------------------------------------------------------------------------------------------------- 1-5
Group 3 Periodic replacement --------------------------------------------------------------------------------------- 1-13
Group 1 Major components -------------------------------------------------------------------------------------------- 2-1
Group 2 Removal and installation of unit ---------------------------------------------------------------------- 2-2
Group 1 Structure and operation ----------------------------------------------------------------------------------- 3-1
Group 2 Troubleshooting ------------------------------------------------------------------------------------------------ 3-19
Group 3 Disassembly and assembly ----------------------------------------------------------------------------- 3-25
Group 1 Structure and function -------------------------------------------------------------------------------------- 4-1
Group 2 Operational checks and troubleshooting -------------------------------------------------------- 4-5
Group 3 Tests and adjustments ------------------------------------------------------------------------------------- 4-7
Group 1 Structure and function -------------------------------------------------------------------------------------- 5-1
Group 2 Operational checks and troubleshooting -------------------------------------------------------- 5-10
Group 3 Disassembly and assembly ----------------------------------------------------------------------------- 5-12
Group 1 Structure and function -------------------------------------------------------------------------------------- 6-1
Group 2 Operational checks and troubleshooting -------------------------------------------------------- 6-17
Group 3 Disassembly and assembly ----------------------------------------------------------------------------- 6-21
Group 1 Component location ----------------------------------------------------------------------------------------- 7-1
Group 2 Electrical circuit ------------------------------------------------------------------------------------------------- 7-2
Group 3 Component Specification --------------------------------------------------------------------------------- 7-10
Group 4 Connector Destination -------------------------------------------------------------------------------------- 7-11
Group 5 Troubleshooting ------------------------------------------------------------------------------------------------ 7-13
CONTENTS
CONTENTS

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Summarization of Contents

Section 1 General
Group 1 Safety Hints
General safety guidelines for operation and maintenance.
Group 2 Specifications
Technical specifications for the machine.
Group 3 Periodic Replacement
Schedule for replacing consumable parts.
Section 2 Removal & Installation
Group 1 Major Components
Identification of major machine components.
Group 2 Removal and Installation of Unit
Procedures for removing and installing major units.
Section 3 Power Train System
Group 1 Structure and Operation
Explanation of the power train system's structure and function.
Group 2 Troubleshooting
Common issues and solutions for the power train system.
Group 3 Disassembly and Assembly
Steps for disassembling and assembling the power train system.
Section 4 Brake System
Group 1 Structure and Function
Description of the brake system's structure and operation.
Group 2 Operational Checks and Troubleshooting
Checks and troubleshooting for the brake system.
Group 3 Tests and Adjustments
Procedures for testing and adjusting the brake system.
Section 5 Steering System
Group 1 Structure and Function
Explanation of the steering system's structure and function.
Group 2 Operational Checks and Troubleshooting
Checks and troubleshooting for the steering system.
Group 3 Disassembly and Assembly
Procedures for disassembling and assembling the steering system.
Section 6 Hydraulic System
Group 1 Structure and Function
Description of the hydraulic system's structure and function.
Group 2 Operational Checks and Troubleshooting
Checks and troubleshooting for the hydraulic system.
Group 3 Disassembly and Assembly
Procedures for disassembling and assembling the hydraulic system.
Section 7 Electrical System
Group 1 Component Location
Identification of electrical system components.
Group 2 Electrical Circuit
Diagrams of the electrical circuits.
Group 3 Component Specification
Specifications for electrical components.
Group 4 Connector Destination
Pin assignments and destinations for connectors.
Group 5 Troubleshooting
Troubleshooting common electrical system issues.
Section 8 Mast
Group 1 Structure
Structural overview of the mast assembly.
Group 2 Operational Checks and Troubleshooting
Checks and troubleshooting for mast operation.
Group 3 Adjustment
Procedures for adjusting mast components.
Group 4 Removal and Installation
Steps for removing and installing the mast.
Foreword
1. Structure
Overview of the service manual's purpose and structure.
Section 1 General
General information and safety hints for the machine.
Section 2 Removal & Installation of Unit
Procedures for removing and installing components.
Section 3 Power Train System
Explanation of the transmission and drive axle.
Section 4 Brake System
Description of brake piping and operation.
Section 5 Steering System
Details on steering unit, circuit, and operation.
Section 6 Hydraulic System
Explanation of hydraulic components and operation.
Section 7 Electrical System
Information on electrical circuits and components.
Section 8 Mast
Details on mast, carriage, backrest, and forks.
2. How to Read the Service Manual
Distribution and Updating
Information on manual updates sent to distributors.
Filing Method
Instructions on filing manual pages correctly.
Revised Edition Mark
Explanation of edition marks on revised pages.
Revisions
Location of revised pages in the manual.
Symbols
Explanation of symbols used for safety and technical information.
3. Conversion Table
Method of Using the Conversion Table
Explanation of how to use the conversion table.
Example
Example of converting millimeters to inches using the table.
Temperature
Fahrenheit-Centigrade Conversion
Table for converting Fahrenheit to Centigrade and vice versa.
Section 1 General
Group 1 Safety Hints
General safety guidelines for operation and maintenance.
Group 2 Specifications
Technical specifications for the machine.
Group 3 Periodic Replacement
Schedule for replacing consumable parts.
Group 1 Safety Hints
Group 2 Specifications
1. General Locations
Diagram showing the general locations of major components.
2. Specifications
3. Specification for Major Components
1) Engine
Specifications for the engine.
2) Main Pump
Specifications for the main hydraulic pump.
3) Main Control Valve
Specifications for the main control valve.
4) Power Train Devices
4. Tightening Torque for Major Components
5. Torque Chart
Bolt and Nut
Torque values for bolts and nuts (coarse and fine threads).
2) Pipe and Hose (Flare type)
3) Pipe and Hose (ORFS type)
4) Fitting
6. Recommended Lubricants
Group 3 Periodic Replacement
Section 2 Removal & Installation of Unit
Group 1 Structure
Identification of major components for removal/installation.
Group 2 Removal and Installation of Unit
Procedures for removing and installing units.
Group 1 Major Components
Group 2 Removal and Installation of Unit
1. Mast
Removal procedures for mast components.
2. Power Train Assembly
1) Removal
Removal procedures for power train components.
3. Engine
1) Removal
Removal procedures for the engine assembly.
4. Steering Axle
1) Removal
Removal procedures for the steering axle.
Section 3 Power Train System
Group 1 Structure and Operation
Explanation of the power train system's structure and function.
Group 2 Troubleshooting
Common issues and solutions for the power train system.
Group 3 Disassembly and Assembly
Steps for disassembling and assembling the power train system.
Group 1 Structure and Operation
1. Power Train Diagram
Diagram illustrating the power train system layout.
2) Specification
2. Torque Converter
1) Structure
Exploded view and list of torque converter parts.
2) Operation
3) Torque Converter Hydraulic Circuit
3. Transmission
1) Structure
Exploded view and list of transmission components.
2) Installation View
3) Operation
4) Operating Modes
5) Transmission Case and Control Valve
(1) Structure
Exploded view and list of components for transmission case and control valve.
(2) Operation
6) Control Valve
(1) Operation
Explanation of the control valve's operation.
(2) Structure
7) Clutch
(1) Operation
Explanation of clutch operation for forward/reverse modes.
(2) Structure
8) Output Gear
(1) Operation
Explanation of output gear function in forward/reverse.
(2) Structure
Exploded view and list of output gear parts.
4. Drive Axle
1) Installation View
Views of the drive axle installation.
2) Structure
Exploded view and list of drive axle components.
3) Carrier Assembly
(1) Operation
Explanation of carrier sub-assembly operation.
(2) Structure
4) Differential Device
(1) Operation
Explanation of differential device operation and safety.
(2) Structure
Exploded view and list of differential device parts.
Group 2 Troubleshooting
1. Transmission
Troubleshooting common transmission problems.
2. Drive Axle
1. Noise and Vibration
Troubleshooting noise and vibration issues in the drive axle.
2. Oil Leakage
Troubleshooting oil leakage issues in the drive axle.
3. Axle Does Not Revolution
Troubleshooting issues related to the axle not revolving.
4. Brake Does Not Apply
5. Brake Does Not Release
6. Braking Performance
Group 3 Disassembly and Assembly
1. Disassembly of Transmission
Procedures for disassembling the transmission.
2) Disassembling of Gear Assemblies
2. Assembly of Transmission
1) Assembling of Gear Assemblies
Procedures for assembling gear assemblies.
2) Assembling of Transmission Assy
3. Disassembly of Drive Axle
1) Disassembly
Procedures for disassembling the drive axle.
2) Assembly
(1) Carrier sub assembly
Procedures for assembling the carrier sub-assembly.
Adjusting Shim and Pinion Shaft Assembly
Assemble of Parking Sub Assembly
Assemble of Carrier Case Cover Assemble
Adjusting the Gearset Backlash
Adjusting Tooth Contact Pattern of the Gearset
(2) Assemble of Carrier Assembly
(3) Traveling Brake System Assembly
(4) Hub Assembly
Hub Sub Assembly
Procedures for assembling the hub sub-assembly.
(5) Assemble of Hub Sub Assembly
(6) The Rest Part Assembly
(7) Functional Test of Hydraulic Apply Brake
Section 4 Brake System
Group 1 Structure and Function
Overview of the brake system's structure and function.
Group 2 Operational Checks and Troubleshooting
Checks and troubleshooting for the brake system.
Group 3 Tests and Adjustments
Procedures for testing and adjusting the brake system.
Group 1 Structure and Function
1. Outline
General description of the brake systems.
2. Specification
Specifications for disk brake and parking brake.
3. Brake Pedal and Piping
1) Structure
Diagram showing brake pedal and piping structure.
4. Inching Pedal and Linkage
5. Wet Disk Brake
1) Structure
Exploded view of the wet disk brake components.
2) Operation
Explanation of the wet disk brake operation.
Group 2 Operational Checks and Troubleshooting
1. Operational Checks
Operational checks for brake system components.
2. Troubleshooting
Troubleshooting common brake system problems.
Group 3 Tests and Adjustments
1. Air Bleeding of Brake System
Procedure for bleeding air from the brake system.
2. Adjustment of Pedal
Procedures for adjusting brake pedal height and play.
(3) Micro Switch for Parking Brake (if equipped)
2) Inching Pedal
(1) Pedal Height from Floor Plate
Adjustment of the inching pedal height.
(2) Adjust Bolt so that Brake Pedal Interconnects with Inching Pedal at Inching Pedal Stroke 15~20 mm
Adjusting brake pedal linkage to inching pedal.
Section 5 Steering System
Group 1 Structure and Function
Overview of the steering system's structure and function.
Group 2 Operational Checks and Troubleshooting
Checks and troubleshooting for steering system operation.
Group 3 Disassembly and Assembly
Procedures for disassembling and assembling the steering system.
Group 1 Structure and Function
1. Outline (Non Booster Brake)
Diagram and overview of the steering system.
2. Hydraulic Circuit
1) Neutral
2) Left Turn
3) Right Turn
3. Steering Unit
1) Structure
Exploded view and list of steering unit components.
2) Operation
4. Steering Axle
1) Structure
Exploded view and list of steering axle components.
2) Tightening Torque and Specification
Group 2 Operational Checks and Troubleshooting
1. Operational Checks
Operational checks for steering system components.
2. Troubleshooting
Troubleshooting common steering system problems.
Group 3 Disassembly and Assembly
1. Steering Unit
Procedures for disassembling and assembling the steering unit.
2) Tools
(1) Holding Tool
Tool used for holding components during work.
(2) Assembly Tool for O-ring and Kin-ring
Tool for assembling O-rings and kin-rings.
(3) Assembly Tool for Lip Seal
Tool for assembling lip seals.
(4) Assembly Tool for Cardan Shaft
Tool for assembling the cardan shaft.
(5) Assembly Tool for Dust Seal
(6) Torque Wrench
3) Tightening Torque
4) Disassembly
5) Assembly
(1) Assemble Spool and Sleeve
Procedures for assembling the spool and sleeve.
2. Steering Cylinder
1) Structure
Exploded view and list of steering cylinder components.
2) Disassembly
3) Check and Inspection
4) Assembly
3. Trail Axle
1) Structure
Exploded view and list of trail axle components.
2) Check and Inspection
3) Disassembly
4) Assembly
Section 6 Hydraulic System
Group 1 Structure and Function
Overview of the hydraulic system's structure and function.
Group 2 Operational Checks and Troubleshooting
Checks and troubleshooting for hydraulic system operation.
Group 3 Disassembly and Assembly
Procedures for disassembling and assembling hydraulic system components.
Group 1 Structure and Function
1. Hydraulic Circuit
Diagram of the hydraulic system circuit.
1) When the Lift Control Lever is in the Lift Position
2) When the Lift Control Lever is in the Lower Position
3) When the Tilt Control Lever is in the Forward Position
4) When the Tilt Control Lever is in the Backward Position
2. Hydraulic Gear Pump
1) Structure
Exploded view and list of hydraulic gear pump components.
2) Operation
Explanation of the hydraulic gear pump operation.
3. Main Control Valve
1) Structure (4- Spool)
Exploded view and list of main control valve parts.
2) Inlet Section Operation
(2) Operation
3) Lift Section Operation
(2) Lower Position
4) Tilt Section Operation
(2) Tilt Backward Position
5) Main Relief Valve
(1) Pressure Setting
Procedure for setting the main relief valve pressure.
(2) Operation
Explanation of the main relief valve operation.
4. Lift Cylinder
1) Structure
Exploded view and list of lift cylinder components.
5. Tilt Cylinder
1) Structure
Exploded view and list of tilt cylinder components.
6. Free Lift Cylinder
1) Structure
Exploded view and list of free lift cylinder components.
Group 2 Operational Checks and Troubleshooting
1. Operational Checks
Operational checks for hydraulic system components.
2) Hydraulic Oil
Checks and maintenance for hydraulic oil.
3) Control Valve
Checks related to the control valve.
2. Troubleshooting
2) Hydraulic Gear Pump
3) Main Relief Valve
4) Lift Cylinder
Group 3 Disassembly and Assembly
1. Disassembly
Disassembly procedures for hydraulic components.
4) Body and Rear Cover
5) Priority Valve
6) Relief Valve
2. Assembly
1) Preparation
Preparation steps before assembling hydraulic components.
2) Priority Valve
Assembly procedures for the priority valve.
3) Rear Cover and Body
4) Gear
5) Housing
6) Inspection
2. Main Control Valve
1) Structure (4- Spool)
Exploded view and list of main control valve parts.
3. Lift Cylinder
1) Structure
Exploded view and list of lift cylinder components.
2) Disassembly
3) Check and Inspection
4) Assembly
4. Tilt Cylinder
1) Structure
Exploded view and list of tilt cylinder components.
2) Disassembly
3) Check and Inspection
Section 7 Electrical System
Group 1 Component Location
Identification of electrical system components.
Group 2 Electrical Circuit
Diagrams of the electrical circuits.
Group 3 Component Specification
Specifications for electrical components.
Group 4 Connector Destination
Pin assignments and destinations for connectors.
Group 5 Troubleshooting
Troubleshooting common electrical system issues.
Group 1 Component Location
Group 2 Electrical Circuit
Memorandum
1. Power Circuit
1) Operating Flow
Flow of current in the power circuit.
2) Check Point
Check points for the power circuit when the engine is OFF.
Power Circuit
2. Starting Circuit
1) Operating Flow
Flow of current in the starting circuit.
2) Check Point
Check points for the starting circuit.
Starting Circuit
3. Charging Circuit
1) Operating Flow
Flow of current in the charging circuit.
2) Check Point
Check points for the charging circuit.
Charging Circuit
Group 3 Component Specification
Group 4 Connector Destination
Group 5 Troubleshooting
Section 8 Mast
Group 1 Structure
Structural overview of the mast assembly.
Group 2 Operational Checks and Troubleshooting
Checks and troubleshooting for mast operation.
Group 3 Adjustment
Procedures for adjusting mast components.
Group 4 Removal and Installation
Steps for removing and installing the mast.
Group 1 Structure
1. 2 Stage Mast (V Mast)
Exploded view and components of a 2-stage V mast.
2. 2 Stage Mast (VF Mast)
3. 3 Stage Mast (TF Mast)
4. Carriage, Backrest and Fork
Group 2 Operational Checks and Troubleshooting
1. Operational Checks
Operational checks for forks and mast.
2. Mast
Operational checks for mast components.
2. Troubleshooting
1) Mast
Troubleshooting common mast problems.
2) Forks
Group 3 Adjustment
1. Mast Load Roller (V, VF Mast)
Adjustment of mast load rollers for V and VF masts.
2. Mast Load Roller (TF Mast)
INNER AND MIDDLE MAST ROLLER CLEARANCE ADJUSTMENT
Adjustment of inner/middle mast roller clearance for TF mast.
OUTER AND MIDDLE MAST UPPER ROLLER CLEARANCE ADJUSTMENT.
Adjustment of outer/middle mast roller clearance.
3) Carriage Load Roller
4) Mast Back Up Liner
Group 4 Removal and Installation
1. Forks
Procedures for removing and installing forks.
2. Backrest
Procedures for removing and installing the backrest.
3. Carriage Assembly
Procedures for removing and installing the carriage assembly.
2) Side Roller
3) Carriage Load Roller
4) Mast Load Roller and Back Up Liner
(1) 2 Stage Mast (V Mast)
Removal and installation of mast load rollers/back up liners for V mast.
(2) 2 Stage Mast (TF Mast)
Removal and installation of mast load rollers/back up liners for TF mast.
(2) 2 Stage Mast (TF Mast)
(2) 3 Stage Mast (TF Mast)
5) Elevating Mast
(1) Inner Mast (V, VF Mast)
Removal/installation of inner mast for V/VF masts.
(2) Inner and Middle Mast (TF Mast)
Removal/installation of inner and middle masts for TF mast.
6) Chain
(1) Chain Sheave (V, VF Mast)
Procedures for removing and installing chain sheaves for V/VF masts.
(2) Rear Chain Sheave (TF Mast)
Procedures for removing and installing chain sheaves for TF mast.
(3) Chain Wheel Bearing Support (TF Mast)
(4) Rear Chain (TF Mast)
(5) Carriage Chain
(6) Load Chain Inspection and Maintenance
(7) Load Chain Lubrication and Adjustment

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