Hyundai HDF 70-7S Manuals

Manuals and User Guides for Hyundai HDF 70-7S. We have 1 Hyundai HDF 70-7S manual available for free PDF download: Service Manual

Hyundai HDF 70-7S Service Manual

Hyundai HDF 70-7S Service Manual (518 pages)

Brand: Hyundai | Category: Forklifts | Size: 37.2 MB

Table of Contents

Table of Contents

11
- Section 1 General
  15
- Group 1 Safety Hints
  16
- Group 2 Specifications
  20
- Group 3 Periodic Replacement
  28
- Section 2 Removal and Installation of Unit
  29
- Group 1 Structure
  30
- Group 2 Removal and Installation of Unit
  31
- Section 3 Power Train System
  49
- Group 1 Structure and Operation
  49
- Group 2 Operation and Maintenance
  76
- Group 3 Disassembly and Assembly
  103
- Group 4 Adjustment
  175
- Section 4 Brake System
  180
- Group 1 Structure and Function
  181
- Group 2 Operational Checks and Troubleshooting
  197
- Group 3 Tests and Adjustments
  202
- Section 5 Steering System
  205
- Group 1 Structure and Function
  206
- Group 2 Operational Checks and Troubleshooting
  216
- Group 3 Disassembly and Assembly
  218
- Section 6 Hydraulic System
  247
- Group 1 Structure and Function
  248
- Group 2 Operational Checks and Troubleshooting
  262
- Group 3 Disassembly and Assembly
  266
- Section 7 Electrical System
  279
- Group 1 Component Location
  280
- Group 2 Electrical Circuit
  281
- Group 3 Component Specification
  292
- Group 4 Connector Destination
  293
- Group 5 Troubleshooting
  295
General

331
- External View
  332
- Fuel System - Flow Diagram
  334
- Lubrication System - Flow Diagram
  334
- System Flow Diagrams
  334
- Cooling System - Flow Diagram
  335
- Inlet and Exhaust System - Flow Diagram
  335
- Engine Serial Number Location
  336
- Main Specifications
  337
- Disassembling
  340
- Reassembling
  340
- Tips on Disassembling and Reassembling
  340
Service Data

341
- General
  342
- Maintenance Service Data
  342
- Basic Engine
  343
- Fuel System
  346
- Lubrication System
  346
- Cooling System
  347
- Inlet and Exhaust System
  347
- Electrical System
  348
- Basic Engine
  349
- Fuel System
  349
- Major Bolt Tightening Torque
  349
- Tightening Torque Table
  349
- Cooling System
  350
- Electrical System
  350
- Inlet and Exhaust Systems
  350
- Lubrication System
  350
- Metric Automobile Screw Thread
  351
- Metric Course Screw Thread
  351
- Standard Bolt and Nut Tightening Torque
  351
- Standard Stud Tightening Torque
  351
- Regarding Submission of Parts for EPA Exhaust Gas Regulation
  352
Disassembly of Basic Engine

361
- Disassembling and Inspecting Cylinder Head and Valve Mechanism
  362
- Disassembling Rocker Shaft Assembly
  363
- Removing Cylinder Head Bolt
  363
- Removing Rocker Shaft Assembly
  363
- Removing Cylinder Head Assembly
  364
- Removing Valve and Valve Spring
  364
- Removing Valve Stem Seal
  364
- Disassembling and Inspecting Flywheel
  365
- Removing Flywheel
  366
- Removing Rear Plate
  366
- Disassembling and Inspecting Damper, Gear Case, Timing Gear and Camshaft
  367
- Removing Cover
  369
- Removing Crankshaft Pulley and Damper
  369
- Measuring Timing Gear Backlash
  370
- Removing Timing Gear Case
  370
- Measuring Idler Gear and Camshaft Gear End Play
  371
- Removing Fuel Injection Pump
  371
- Removing Oil Pan
  371
- Removing Oil Strainer
  371
- Removing Camshaft
  372
- Removing Idler Gear
  372
- Removing Oil Pump Gear
  372
- Removing PTO Drive Gear
  372
- Installing Camshaft Gear and Thrust Plate
  373
- Removing Front Plate
  373
- Removing Oil Pump
  373
- Separating Camshaft Gear
  373
- Disassembling and Inspecting Piston, Connecting Rod, Crankshaft and Crankcase
  374
- Pulling out Piston
  375
- Removing Carbon Deposits from the Upper Part of Cylinder Liner
  375
- Removing Connecting Rod Cap
  375
- Removing Main Bearing Cap
  376
- Removing Piston Pin and Piston
  376
- Removing Piston Ring
  376
- Removing Crankshaft
  377
- Removing Tappet
  377
Inspection and Repair of Basic Engine

379
Reassembly of Basic Engine

409
- Installing Crankshaft
  410
- Installing Main Bearing
  410
- Installing Tappet
  410
- Installing Thrust Plate
  410
- Reassembling Piston, Connecting Rod, Crankshaft and Crankcase
  410
- Inserting Side Seal
  411
- Installing Main Bearing Cap Bolt
  411
- Installing Main Bearing Caps
  411
- Measuring Crankshaft End Play
  412
- Reassembling Piston and Connecting Rod
  412
- Installing Piston Ring
  413
- Preparation for Installing Pistons
  413
- Installing Connecting Rod Bolt and Connecting Rod Bearing
  414
- Installing Pistons
  414
- Installing Connecting Rod Cap
  415
- Installing Front Plate
  416
- Installing Oil Pump
  416
- Reassembling Timing Gear and Camshaft
  416
- Installing Camshaft
  417
- Installing Camshaft Gear and Thrust Plate
  417
- Installing PTO Drive Gear
  417
- Installing Idler Gear
  418
- Inspecting and Adjusting Timing Gear after Installation
  419
- Inspecting Backlash and End Play
  419
- Installing Fuel Injection Pump
  419
- Installing Oil Pump Gear
  419
- Installing Front Oil Seal
  420
- Installing Oil Strainer
  420
- Installing Timing Gear Case
  420
- Installing Oil Pan
  421
- Installing Cover
  422
- Installing Crankshaft Pulley and Damper
  422
- Installing Flywheel
  423
- Installing Oil Seal
  423
- Installing Rear Plate
  423
- Reassembling Flywheel
  423
- Cleaning Cylinder Head Bottom Surface
  424
- Installing Valve and Valve Spring
  424
- Installing Valve Stem Seal
  424
- Reassembling Cylinder Head and Valve Mechanism
  424
- Installing Cylinder Head Assembly
  425
- Installing Cylinder Head Gasket
  425
- Tightening Cylinder Head Bolts
  425
- Inserting Push Rod
  426
- Installing Rocker Shaft Assembly
  426
- Reassembling Rocker Shaft Assembly
  426
- Adjusting Valve Clearance
  427
- Determining Top Dead Center of No. 1 Cylinder Compression Stroke
  427
- Installing Rocker Cover
  427
- When Replacing the Damper with a New One
  427
- When Reusing the Damper
  427
Fuel System

429
Lubrication System

443
Cooling System

457
- Removing Cooling System
  458
- Removing Thermostat
  458
- Removing Water Pump, Water Pump Pulley and V-Belt
  459
- Disassembling and Inspecting Thermostat
  460
- Disassembling, Inspecting and Reassembling Cooling System
  460
- Inspecting Thermostat
  461
- Disassembling Water Pump
  462
- Inspecting Water Pump
  462
- Installing Cooling System
  463
- Installing Water Pump, Water Pump Pulley and V-Belt
  463
- Installing Thermostat
  464
Inlet and Exhaust Systems

465
- Removing Turbocharger
  466
- Removing Turbocharger, Inlet and Exhaust Systems
  466
- Removing Inlet Manifold
  467
- Removing Exhaust Manifold
  468
- Disassembling, Inspecting and Reassembling Inlet and Exhaust Systems
  469
- Measuring Exhaust Manifold Distortion
  469
- Disassembling and Inspecting Turbocharger
  470
- Installing O-Ring
  471
- Removing Compressor Cover
  471
- Removing Turbine Housing
  471
- Installing Compressor Cover
  472
- Installing Snap Ring
  472
- Cleaning
  473
- Measuring Axial Clearance of Cartridge Assembly
  473
- Reassembling Turbocharger
  474
- Installing Exhaust Manifold
  476
- Installing Turbocharger, Inlet and Exhaust Systems
  476
- Installing Inlet Manifold
  477
- Installing Turbocharger
  478
Electrical System

479
- Removing Electrical System
  480
- Removing Starter
  480
- Handling Precaution
  481
- Inspecting Alternator Operation
  481
- Inspection before Removing Alternator
  481
- Removing Alternator
  482
- Removing Glow Plug
  484
- Disassembling, Inspecting and Reassembling Electrical System
  485
- Inspecting Magnetic Switch
  485
- Inspection before Disassembling Starter
  485
- No Load Test
  486
- Disassembling and Inspecting Starter
  487
- Removing Pinion Set
  488
- Removing Armature and Yoke
  489
- Removing Brush Holder and Brush Assembly
  489
- Removing Magnetic Switch
  489
- Removing Overrunning Clutch
  489
- Removing Rear Bracket
  489
- Inspecting and Repairing Starter
  490
- Inspecting Brush Holder for Insulation
  490
- Inspecting Brushes for Wear
  490
- Measuring Brush Spring Load
  490
- Measuring Commutator Radial Runout
  490
- Checking Armature Coil
  491
- Measuring Commutator Outside Diameter12-13
  491
- Measuring Undercut Depth
  491
- Inspecting Field Coil
  492
- Inspecting Front Bracket
  492
- Inspecting Gears of Starter
  492
- Inspecting Overrunning Clutch Operation
  492
- Inspecting Rear Bracket
  492
- Inspecting Magnetic Switch
  493
- Inspecting Starter Relay
  493
- Installing Gear Shaft
  494
- Reassembling Starter
  494
- Disassembling and Inspecting Alternator12-17
  495
- Separating Front Bracket from Stator
  495
- Removing Field Coil
  496
- Removing Pulley
  496
- Removing Rear Bearing
  496
- Removing Front Bearing
  497
- Removing Rectifier Assembly
  497
- Removing Regulator Assembly
  497
- Removing Stator
  497
- Inspecting and Repairing Alternator
  498
- Inspecting Rectifier
  498
- Inspecting Stator
  498
- Measuring Field Coil
  499
- Installing Rectifier Assembly and Regulator Assembly
  500
- Reassembling Alternator
  500
- Installing Front Bearing
  501
- Installing Pulley
  501
- Installing Rear Bearing
  501
- Installing Stator
  501
- Assembling Stator and Front Bracket
  502
- Continuity Test of Glow Plug
  502
- Heating Test of Glow Plug
  502
- Inspecting Glow Plug
  502
- Continuity Test of Magnetic Valve
  503
- Inspecting Magnetic Valve (Stop Solenoid)
  503
- Inspecting Magnetic Valve (Stop Solenoid) Operation
  503
- Installing Magnetic Valve (Stop Solenoid)12-25
  503
- Installing Electrical System
  504
- Installing Glow Plug
  504
- Installing Alternator
  505
- Installing Starter
  507
Adjustment and Operation

509
- Adjusting Engine
  510
- Adjusting Valve Clearance
  510
- Inspecting and Adjusting Valve Clearance13-2
  510
- Inspecting Valve Clearance
  510
- Bleeding Fuel Filter
  511
- Bleeding Fuel System
  511
- Draining Fuel Filter
  511
- Draining Fuel System
  511
- Adjusting Fuel Injection Timing
  512
- Inspecting and Adjusting Fuel Injection Timing
  512
- Adjusting V-Belt Tension
  515
- Inspecting V-Belt
  515
- Inspecting V-Belt and Adjusting V-Belt Tension
  515
- Break-In Operation
  516
- Break-In Operation Time
  516
- Inspecting Engine Condition after Starting up
  516
- Inspection and Adjustment after Break-In Operation
  516
- Starting up
  516
- Continuous Load Test
  517
- Engine Equipment Condition
  517
- Engine Output Adjustment
  517
- Low Idle Test
  517
- Operation Load Test
  517
- Other Inspections
  517
- Performance Test (JIS Standard)
  517
- Standard Atmospheric Conditions
  517
- Test Items and Purposes
  517
- Calculation of Corrected Power
  518

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