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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
Foreword
1. Structure of the Service Manual
Details the organization of the service manual into various sections for clarity.
Section 1: General Information
Provides general information about the machine and safety hints for maintenance.
Section 2: Removal & Installation of Unit
Explains the procedures and techniques for removing and installing each component.
Section 3: Power Train System
Explains the structure of the transmission, control valve, and drive axle.
Section 4: Brake System
Explains the brake piping, components, and operation.
Section 5: Steering System
Explains the steering unit, hydraulics, and operation.
Section 6: Hydraulic System
Explains the hydraulic pump, control valve, and circuits.
Section 7: Electrical System
Explains the electrical circuits and components.
Section 8: Mast Components
Explains the structure of the mast, carriage, backrest, and forks.
How to Read the Service Manual
Symbols for Safety and Quality
Explains symbols used to mark important places for safety and quality.
Section 1: General Information and Safety
Group 1: Safety Hints for Operation
Provides essential safety precautions and guidelines for operating the equipment safely.
Group 2: Component Specifications
Lists detailed technical specifications for various machine components.
Group 3: Periodic Replacement Schedule
Outlines the recommended schedule for replacing consumable and wear-prone parts.
Section 2: Unit Removal and Installation Procedures
Group 1: Structure of the Unit
Details the structural layout and components of the unit for reference.
Group 2: Unit Removal and Installation Guide
Step-by-step instructions for the removal and installation of the unit.
Section 3: Power Train System Overview
Group 1: Power Train Structure and Operation
Explains the components, structure, and operational principles of the power train system.
Group 2: Power Train Inspection and Troubleshooting
Covers methods for inspecting and diagnosing issues within the power train system.
Group 3: Power Train Disassembly and Assembly
Provides detailed procedures for disassembling and assembling the power train components.
Section 4: Brake System: Structure, Operation, and Maintenance
Group 1: Brake System Structure and Function
Explains the fundamental structure and operational principles of the brake system.
Group 2: Brake Operational Checks and Troubleshooting
Guides through operational checks and common troubleshooting steps for the brake system.
Group 3: Brake System Tests and Adjustments
Details procedures for testing and adjusting the brake system components.
Section 5: Steering System: Components, Operation, and Service
Group 1: Steering System Structure and Function
Explains the structure and functional principles of the steering system.
Group 2: Steering Operational Checks and Troubleshooting
Covers operational checks and troubleshooting for common steering system issues.
Group 3: Steering Disassembly and Assembly
Provides steps for disassembling and assembling steering system components.
Section 6: Hydraulic System: Circuits, Operation, and Maintenance
Group 1: Hydraulic System Structure and Function
Explains the structure and functional principles of the hydraulic system.
Group 2: Hydraulic Operational Checks and Troubleshooting
Covers operational checks and troubleshooting for the hydraulic system.
Group 3: Hydraulic Disassembly and Assembly
Provides steps for disassembling and assembling hydraulic components.
Section 7: Electrical System: Components and Troubleshooting
Group 1: Electrical System Component Location
Identifies the physical locations of key electrical system components.
Group 2: Electrical System Circuit Diagrams
Presents the detailed electrical circuit diagrams for the machine.
Group 3: Electrical Component Specifications
Lists the specifications for individual electrical components.
Group 4: Electrical Connector Destinations
Details connector destinations and associated part numbers for wiring.
Group 5: Electrical System Troubleshooting
Guides users through diagnosing and resolving electrical system problems.
Section 8: Mast System: Structure, Operation, and Service
Group 1: Mast Structure Details
Explains the structural components of the mast system, including different stages.
Group 2: Mast Operational Checks and Troubleshooting
Covers operational checks and troubleshooting procedures for the mast.
Group 3: Mast Adjustment Procedures
Details the steps for adjusting critical mast components for proper function.
Group 4: Mast Removal and Installation
Provides step-by-step instructions for removing and installing mast assemblies.
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