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FOREWORD
1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to
full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
SECTION 1 GENERAL
This section gives the general information of the machine and explains the safety hints for
maintenance.
SECTION 2 REMOVAL & INSTALLATION OF UNIT
This section explains the procedures and techniques of removal and installation of each component.
SECTION 3 POWER TRAIN SYSTEM
This section explains the structure of the transmission as well as control valve and drive axle.
SECTION 4 BRAKE SYSTEM
This section explains the brake piping, each component and operation.
SECTION 5 STEERING SYSTEM
This section explains the structure of the steering unit, priority valve, trail axle as well as steering
circuit and operation.
SECTION 6 HYDRAULIC SYSTEM
This section explains the structure of the gear pump, main control valve as well as work equipment
circuit, each component and operation.
SECTION 7 ELECTRICAL SYSTEM
This section explains the electrical circuit and each component.
It serves not only to give an understanding electrical system, but also serves as reference material for
troubleshooting.
SECTION 8 MAST
This section explains the structure of mast, carriage, backrest and forks.
The specifications contained in this service manual are subject to change at any time and without any
advance notice. Contact your HYUNDAI distributor for the latest information.
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Summarization of Contents
1. Structure Overview
Section 1 General Information
General information and safety hints for machine maintenance.
Section 2 Removal and Installation of Unit
Procedures and techniques for removing and installing components.
Section 3 Power Train System
Explains the structure of the power train system.
Section 4 Brake System
Explains the brake system components and operation.
Section 5 Steering System
Explains the steering system components and operation.
Section 6 Hydraulic System
Explains the hydraulic system components and operation.
Section 7 Electrical System
Explains electrical circuits and components for troubleshooting.
Section 8 Mast
Explains the structure of mast, carriage, backrest, and forks.
2. How to Read the Service Manual
Filing Method and Page Numbering
Guides on how to file manual pages correctly and read page numbers.
Symbols Explanation
Explains symbols used for safety and quality.
3. Conversion Table Guide
Using the Conversion Table
Guides on how to use the conversion table for figures.
SECTION 1 GENERAL
Group 1 Safety Hints
Safety guidelines for operating the machine.
Group 2 Specifications
Technical specifications of the machine's components.
Group 3 Periodic Replacement
Schedule for periodic replacement of consumable parts.
GROUP 2 Specifications
1. Major Components
Lists and illustrates the main components of the machine.
3. Specification for Major Components
1) Engine Specifications
Detailed specifications for the engine.
(2) Main Pump Specifications
Specifications for the main hydraulic pump.
(3) Main Control Valve Specifications
Specifications for the main control valve.
(4) Power Train Devices Specifications
Torque Converter Specifications
Specifications for the torque converter.
Transmission Specifications
Specifications for the transmission system.
Axle and Brakes Specifications
Specifications for the axle and brake systems.
Steering Specifications
Specifications for the steering system.
4. Tightening Torque for Major Components
Engine and Hydraulic System Torques
Tightening torques for engine and hydraulic components.
Power Train System and Other Torques
Tightening torques for power train and other components.
5. Torque Chart
Bolt and Nut Torque Specifications
Torque chart for bolts and nuts (coarse and fine threads).
Pipe and Hose Torque Specifications
Flare Type Pipe and Hose Torques
Torque specifications for flare type pipes and hoses.
ORFS Type Pipe and Hose Torques
Torque specifications for ORFS type pipes and hoses.
Fitting Torque Specifications
Torque specifications for fittings.
6. Recommended Lubricants
Lubricant Selection by Service Point and Temperature
Lists lubrication points and recommended fluids based on temperature.
Lubricant Notes
Important notes regarding lubricant selection and usage.
GROUP 3 Periodic Replacement
Consumable Parts Replacement Schedule
Schedule for periodic replacement of consumable parts.
SECTION 2 Removal & Installation of Unit
Group 1 Structure Overview
Illustrates the structure of the unit.
Group 2 Removal and Installation Procedures
Outlines the removal and installation process.
GROUP 1 STRUCTURE
Mast and Lift Cylinder Structure
Illustrates the mast and lift cylinder components.
Steering Unit and Tilt Cylinder Structure
Illustrates the steering unit and tilt cylinder components.
Control Valve, Fork, and Wheels Structure
Illustrates control valve, fork, and wheel components.
Drive Axle, Hydraulic Pump, and Transmission Structure
Illustrates drive axle, hydraulic pump, and transmission components.
Engine, Air Cleaner, and Exhaust Pipe Structure
Illustrates engine, air cleaner, and exhaust pipe components.
Steering Axle, Rear Wheel, and Tail Pipe Structure
Illustrates steering axle, rear wheel, and tail pipe components.
Radiator, Muffler, and LPG Tank Structure
Illustrates radiator, muffler, and LPG tank components.
Overhead Guard, Seat, and Lever Structure
Illustrates overhead guard, seat, and lever components.
Steering Wheel Structure
Illustrates the steering wheel component.
GROUP 2 Removal and Installation of Unit
1. Mast Removal
Steps for removing mast components.
2. Installation of Mast Components
Mast Mounting Pin Installation
Steps for installing the mast mounting pin.
Tilt Cylinder Pin Installation
Steps for installing the tilt cylinder pin.
Lift Cylinder Installation and Adjustment
Steps for installing and adjusting the lift cylinder.
2. Power Train Assembly Removal
Mast Removal Reference
Reference to mast removal section.
2. Power Train Assembly Installation
Tightening Torque Specifications
Specifies tightening torques for installation.
3. Engine Removal
Overhead Guard Removal
Steps for removing the overhead guard.
5. Steering Axle Removal
Counterweight Removal
Steps for removing the counterweight.
SECTION 3 Power Train System
Group 1 Structure and Operation
Explains the structure and operation of the power train.
Group 2 Inspection and Troubleshooting
Covers inspection and troubleshooting for the power train.
Group 3 Disassembly and Assembly
Details disassembly and assembly procedures for the power train.
GROUP 1 Structure and Operation
1. Power Train Component Overview
Overview of power train components.
2. Specifications
Torque Converter Specifications
Specifications for the torque converter.
Transmission Specifications
Specifications for the transmission.
Drive Axle and Differential Specifications
Specifications for the drive axle and differential.
2. Torque Converter
1) Structure
Illustrates the structure of the torque converter.
2) Operation
Explains the operation of the torque converter.
3. Transmission
1) Structure
Illustrates the structure of the transmission.
2) Operation
Explains the operation of the transmission.
4) Transmission Input Port Pressure
Transmission Pressure Readings
Table of transmission pressures at different engine RPMs.
5) Transmission Input Port Hydraulic Circuit
Hydraulic Circuit Specifications
Specifications for the transmission input port hydraulic circuit.
Electric Input Data
Electric input data for the transmission.
4. Differential Carrier Assembly Structure
Differential Carrier Structure
Illustrates the structure of the differential carrier.
Differential Operation
Explains the operation of the differential.
5. Drive Axle
1) Structure
Illustrates the structure of the drive axle.
2) Operation
Explains the operation of the drive axle.
GROUP 2 Inspection and Troubleshooting
1. Inspection Procedures
Procedures for inspecting the transmission.
2. Troubleshooting: Operation Issues
Checklist During Operation
Lists common operational problems and their causes/remedies.
4) Drive Axle Troubleshooting
Differential Noise Issues
Troubleshooting for differential noise.
Drive Axle Oil Leakage
Troubleshooting for oil leakage issues.
GROUP 3 Disassembly and Assembly
1. Drive Axle Disassembly
Steps to disassemble the drive axle.
2. Drive Axle Redisassembly
1) Bevel Pinion Shaft Adjustment
Steps to adjust the bevel pinion shaft shim thickness.
3. Transmission Disassembly
Torque Converter Removal
Steps to remove the torque converter.
PTO Input Removal
Steps to remove PTO input from torque converter.
Housing Bolt and Seal Removal
Steps to remove bolts, washes, oil seal from housing.
Plug, Spring, and Ball Removal
Steps to remove plug, O-ring, spring, ball.
Valve and Spring Removal
Steps to remove plug, spring, valve.
4. Transmission Assembly
General Cleaning and Seal Installation
General cleaning and seal installation instructions for transmission.
Bearing Cup Installation
Instructions for installing bearing cups.
Output Shaft Gear and Bearing Installation
Instructions for installing gear and bearing on output shaft.
38. Shim Thickness Calculation and Assembly
Shaft Assembly and Case Installation
Steps to assemble shaft assemblies and install transmission case.
Shaft Shim Measurement Method
Method for measuring shaft shim.
Shim Selection and Shaft Smoothness Check
Shim selection criteria and troubleshooting for shaft rotation.
39-41. Torque Converter Housing and PTO Input Installation
Torque Converter Housing Installation
Steps to install torque converter housing.
PTO Input and Torque Converter Installation
Steps to install PTO input and torque converter.
SECTION 4 Brake System
Group 1 Structure and Function
Explains the structure and function of the brake system.
Group 2 Operational Checks and Troubleshooting
Covers operational checks and troubleshooting for the brake system.
Group 3 Tests and Adjustments
Details tests and adjustments for the brake system.
GROUP 1 Structure and Function
1. Brake System Outline
Provides an overview of the brake systems.
2. Brake System Specifications
Details specifications for disk and parking brakes.
GROUP 2 Operational Checks and Troubleshooting
1. Operational Checks
Procedures for operational checks of brake system.
GROUP 3 Tests and Adjustments
1. Air Bleeding of Brake System
Procedure for bleeding air from the brake system.
2. Pedal Adjustments
Adjustments for brake and inching pedals.
SECTION 5 Steering System
Group 1 Structure and Function
Explains the structure and function of the steering system.
Group 2 Operational Checks and Troubleshooting
Covers operational checks and troubleshooting for the steering system.
Group 3 Disassembly and Assembly
Details disassembly and assembly procedures for the steering system.
GROUP 1 Structure and Function
1. Steering System Outline
Provides an overview of the steering system and its components.
2) Greasing and Specifications
Knuckle and Steering Axle Specifications
Details knuckle structure and alignment specifications.
Wheel Alignment Specifications
Specifications for toe-in, camber, caster, king pin angle, and tread.
Maximum Steering Angle Specification
Specification for maximum steering angles.
GROUP 2 Operational Checks and Troubleshooting
1. Operational Checks
Procedures for checking steering system components.
GROUP 3 Disassembly and Assembly
1. Steering Unit Disassembly
Steps to disassemble the steering unit.
2) Tools for Steering System
Holding Tool
Describes the holding tool used for steering unit assembly.
Assembly Tools for Seals and Shafts
Describes assembly tools for O-rings, kin-rings, lip seals, and cardan shafts.
Assembly Tool for Dust Seal
Describes the assembly tool for dust seals.
Torque Wrenches and Spanners
Lists required torque wrenches and spanners.
4) Disassembly: Steering Unit
Steering Column Disassembly
Steps to disassemble the steering column.
End Cover and Gearwheel Set Removal
Steps to remove the end cover and gearwheel set.
Cardan Shaft Removal
Steps to remove the cardan shaft.
5) Assembly: Steering Unit
Spool and Sleeve Assembly
Steps to assemble the spool and sleeve.
Neutral Position Springs Placement
Steps to place neutral position springs.
Spring Set Alignment
Procedure to align the spring set.
Spool and Sleeve Guidance
Steps to guide the spool into the sleeve.
2. Steering Cylinder
1) Structure
Illustrates the structure of the steering cylinder.
3) Steering Cylinder Check and Inspection
Piston Seal Installation
Steps to install a new piston seal.
Rod Seal Installation
Steps to install the rod seal.
SECTION 6 Hydraulic System
Group 1 Structure and Function
Explains the structure and function of the hydraulic system.
Group 2 Operational Checks and Troubleshooting
Covers operational checks and troubleshooting for the hydraulic system.
Group 3 Disassembly and Assembly
Details disassembly and assembly procedures for the hydraulic system.
GROUP 1 Structure and Function
1. Hydraulic Circuit Diagram
Illustrates the hydraulic circuit diagram.
3. Main Control Valve Structure
Main Control Valve: Two Spool Structure
Illustrates the structure of the main control valve with two spools.
2) Lift Section Operation
Lift Position Operation
Explains operation in the lift position.
3) Tilt Section Operation
Tilt forward position
Explains operation in the tilt forward position.
4) Main Relief Valve
1) Pressure Setting
Procedure for setting the pressure of the main relief valve.
2) Function: As Work Port Relief
Explains the function of the relief valve as a work port relief.
Function: As Anti-Void Unit
Explains the function of the anti-void unit.
4. Lift Cylinder
1) Structure
Illustrates the structure of the lift cylinder.
5. Tilt Cylinder
1) Structure
Illustrates the structure of the tilt cylinder.
GROUP 2 Operational Checks and Troubleshooting
1. Operational Checks
Procedures for checking hydraulic system components.
2. Troubleshooting: Hydraulic System
1) System Troubleshooting
Troubleshooting for common hydraulic system problems.
GROUP 3 Disassembly and Assembly
1. Main Pump Structure
Illustrates the structure of the main pump.
2) General Instructions for Pump Service
Cleanliness and Lubrication
General instructions for pump cleanliness and lubrication.
Pump Disassembly Preparation
Preparation steps prior to pump disassembly and assembly.
4) Assembly: Main Pump
Cover Assembly
Steps for assembling the pump cover.
2. Main Control Valve
1) Assemble Valve Components
Steps to assemble valve components.
Tie Rod Nut Assembly
Steps to assemble tie rod nuts.
Spool Section Placement
Steps to place spool sections and O-rings.
End Section Positioning
Steps to position and tighten end sections.
4. Lift Cylinder
1) Structure
Illustrates the structure of the lift cylinder.
3) Lift Cylinder Check and Inspection
Piston Seal Installation
Steps to install a new piston seal.
Rod Seal Installation
Steps to install the rod seal.
5. Tilt Cylinder
1) Structure
Illustrates the structure of the tilt cylinder.
SECTION 7 Electrical System
Group 1 Component Location
Identifies the location of electrical components.
Group 2 Electrical Circuit
Provides the electrical circuit diagram.
Group 3 Component Specification
Lists specifications for electrical components.
Group 4 Connector Destination
Details connector destinations and part numbers.
Group 5 Troubleshooting
Covers troubleshooting for electrical system issues.
GROUP 1 Component Location
Electrical Component Locations
Illustrates the location of various electrical components on the machine.
GROUP 2 Electrical Circuit
Main Electrical Circuit Diagram
Provides the overall electrical circuit diagram for the machine.
1. Power Circuit
1) Operating Flow
Describes the flow of current in the power circuit.
2) Check Points
Lists check points and voltages for the power circuit.
2. Starting Circuit
1) Operating Flow
Describes the operating flow of the starting circuit.
2) Check Points
Lists check points and voltages for the starting circuit.
GROUP 3 Component Specification
Electrical Component Specifications
Lists specifications for various electrical components.
GROUP 4 Connector Destination
Connector Mapping and Part Numbers
Details connector destinations and part numbers for wiring harnesses.
GROUP 5 Troubleshooting
Electrical System Troubleshooting
Lists common electrical system problems and their causes/remedies.
SECTION 8 Mast
Group 1 Mast Structure
Explains the structure of the mast.
Group 2 Mast Operational Checks and Troubleshooting
Covers operational checks and troubleshooting for the mast.
Group 3 Mast Adjustment
Details adjustment procedures for the mast.
Group 4 Mast Removal and Installation
Details removal and installation procedures for the mast.
GROUP 1 STRUCTURE
1. 2 Stage Mast (V Mast) Structure
Illustrates the structure of a 2-stage mast.
GROUP 2 Operational Checks and Troubleshooting
1. Operational Checks
Procedures for checking forks and mast.
2. Troubleshooting: Mast Issues
1) Mast Troubleshooting
Troubleshooting for mast lifting and noise issues.
2) Forks Troubleshooting
Fork Abrasion, Distortion, and Fatigue
Troubleshooting for fork abrasion, distortion, and fatigue.
GROUP 3 Adjustment
1. Mast Load Roller Clearance Adjustment (V, VF Mast)
Steps to adjust clearance between mast rollers for V/VF masts.
2. Mast Load Roller Clearance Adjustment
Inner and Middle Mast Roller Clearance Adjustment (TF Mast)
Steps to adjust clearance for inner/middle mast rollers.
Outer and Middle Mast Upper Roller Clearance Adjustment
Steps to adjust clearance for outer/middle mast upper rollers.
GROUP 4 Removal and Installation
1. Forks Removal and Installation
Procedures for removing and installing forks.
2. Backrest Removal and Installation
Procedures for removing and installing the backrest.
3. Carriage Assembly
Steps for assembling the carriage.
2) Side Roller Procedures
Side Roller Removal, Cleaning, and Adjustment
Steps for removing, cleaning, and adjusting side rollers.
3) Carriage Load Roller Procedures
Carriage Load Roller Removal and Assembly
Steps for removing and assembling carriage load rollers.
4) Mast Load Roller and Back Up Liner Removal
2 Stage Mast (V Mast) Procedures
Steps for removing mast load rollers and back up liners for V mast.
5) Elevating Mast Procedures
Inner Mast Removal (V, VF Mast)
Steps for removing the inner mast for V/VF masts.
Inner and Middle Mast Removal (TF Mast)
Steps for removing inner and middle mast for TF mast.
6) Chain Procedures
Chain Sheave Removal (V, VF Mast)
Steps for removing chain sheaves for V/VF masts.
Rear Chain Removal (TF Mast)
Steps for removing rear chains for TF mast.
Adjustment: Chain Length
Reasons for Chain Adjustment
Reasons why chain adjustments are important.
Chain Adjustment Procedure
Steps to adjust chain length.
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