PDF Service Manual Hyundai 22B-7, 25B-7, 30B-7, 32B-7 Forklift - 3 MB
This is the complete service manual for the Hyundai Forklift Truck B-7 series, including models 22B-7, 25B-7, 30B-7, and 32B-7.
It contains all the information a professional technician needs to perform maintenance, troubleshooting, and major repairs.
With detailed instructions and specifications for all systems, this manual is essential for servicing your Hyundai forklift to factory standards.
Ensure safety and reliability by following the expert guidance within this manual.
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--- Page 1 ---
CONTENTS
SECTION 1 GENERAL
Group 1 Safety hints - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
Group 2 Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-4
Group 3 Periodic replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-12
SECTION 2 REMOVAL & INSTALLATION OF UNIT
Group 1 Major components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
Group 2 Removal and Installation of Unit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
SECTION 3 POWER TRAIN SYSTEM
Group 1 Structure and operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
Group 2 Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-4
Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-5
SECTION 4 BRAKE SYSTEM
Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-5
Group 3 Tests and adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-7
SECTION 5 STEERING SYSTEM
Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-10
Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-13
SECTION 6 HYDRAULIC SYSTEM
Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-16
Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-20
SECTION 7 ELECTRICAL SYSTEM
Group 1 Component location - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1
Group 2 Electrical circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-2
Group 3 Electric components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
SECTION 8 MAST
Group 1 Structure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1
Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-4
Group 3 Adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-7
Group 4 Removal and installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-10
--- Page 3 ---
GROUP 1 SAFETY HINTS
Careless performing of the easy work may
cause injuries.
Take care to always perform work safely, at least
observing the following.
 Oil is a dangerous substance. Never handle
oil, grease or oily clothes in places where
there is any fire of flame.
As preparation in case of fire, always know
the location and directions for use of fire
D50ASF01
extinguishers and other fire fighting
equipment.
 Wear well-fitting helmet, safety shoes and
working clothes. When drilling, grinding or
hammering, always wear protective goggles.
Always do up safety clothes properly so that
they do not catch on protruding parts of
machines. Do not wear oily clothes.
When checking, always release battery plug.
D50ASF02
 Flames should never be used instead of
lamps. Never use a naked flame to check
leaks or the level of oil or electrolyte.
D50ASF03
 When working on top of the machine, be
careful not to lose your balance and fall.
D50ASF06
1-1
--- Page 4 ---
6. RECOMMENDED LUBRICANTS
Use only oils listed below or equivalent.
Do not mix different brand oil.
Capacity ˶ (U.S. gal Ambient temperature Á
C(Á
F)
Service Kind of -20 -10 0 10 20 30 40
point fluid 22/25/30/32B-7
(-4) (14) (32) (50) (68) (86) (104)
2.4
Axle Gear oil Mobilfluid 424
(0.63)
ISO VG 22
Hydraulic Hydraulic 24
oil tank oil (6.3) ISO VG 46
ISO VG 68
Brake 0.5
Brake oil SAE 10W HYDRAULIC OIL (AZOLA ZS10)
system (0.1)
Fitting NLGI No.1
0.1
(Grease Grease
(0.03)
nipple) NLGI No.2
ÂAPI : American Petroleum Institute
ÂSAE : Society of Automotive Engineers
ÂISO : International Organization for Standardization
ÂNLGI : National Lubricating Grease Institute
1-11
--- Page 5 ---
(4) Drive unit & motor assy
ö Drain the oil before disassembling the
drive unit.
Frame
Η Unscrew ten wheel nuts and remove the
wheel.
Motor
wiring
Drive unit &
motor assy
Wheel nut
22B7RE15
Θ Remove five socket bolts holding the
drive motor in place.
Ι Carefully remove the drive motor from the
Socket bolt
drive unit.
Drive motor
Drive unit
22B7RE16
Κ Loosen six mounting bolts on the truck Nut
frame and carefully take out the drive
unit.
Frame
Drive unit
Mounting bolt
22B7RE17
2) INSTALLATION
1
Installation is the reverse order of removal,
but be careful of the following tightening
Frame
torque.
ÂTightening torque Motor
wiring
Item kgfÂm lbfÂft 2
Drive motor (1) 6~8 43.4 ~ 57.9
3
Drive unit (2) 53 ~ 58 383 ~ 420 22B7RE18
Wheel nut (3) 12.5 ~ 15.5 90.4 ~ 112
2-8
--- Page 6 ---
GROUP 3 DISASSEMBLY AND ASSEMBLY
1. DRIVE UNIT
1) DISASSEMBLY
(1) Drive unit assembly.
22B7DX001
(2) Loosen the drain plug and drain oil.
22B7DX002
(3) Remove the housing bolt.
22B7DX03
(4) Remove the cover from the housing.
22B7DX004
3-5
--- Page 7 ---
Λ Assemble the needle bearing.
22B7DX056
Μ Needle bearing is now assembled.
22B7DX013
Ν Assemble the planetary gear.
22B7DX012
Ξ Assemble the washer.
22B7DX059
Ο Assemble the retaining ring of planetary gear.
22B7DX060
3-15
--- Page 8 ---
Ν Apply the loctite #577 on the magnetic plug and
assemble it.
ÂTightening torque : 3.0~4.1kgfÂm(21.7~29.7lbfÂft)
22B7DX124
Ξ Apply the loctite #577 on the air breather and
assemble it.
22B7DX126
(5) Adjusting lever stroke
Η Assemble the lever and pin.
22B7DX127
Θ Assemble the adapter for a pressure
measurement.
22B7DX128
22B7DX129
3-25
--- Page 9 ---
GROUP 3 TESTS AND ADJUSTMENTS
1. BLEED THE BRAKE SYSTEM
The brake system must be bleeded after
replenishing with brake fluid.
1) Remove cap from bleeding valve and fit
proper hose to collect escaping brake fluid
in a vessel.
2) Apply pressure by operating the brake
pedal. Bleeding valve
3) Open bleeding valve approx. half a turn with
a spanner and press the brake pedal
simultaneously to bleed the system. 22B7BS08
ö Collect escaping brake fluid into a suitable vessel.
Do not drain brake fluid into the soil or the gutters.
Close the bleeding valve before releasing the brake pedal.
ö Repeat this procedure until the brake fluid escapes without bubbles.
Check the brake fluid container for sufficient fluid and refill if necessary.
4) When brake fluid escapes without bubbles tighten bleeding valve, remove hose and put dust
protector onto the bleeding valve.
ÂTightening torque : 5kgfÂm (37lbfÂft)
2. ADJUSTMENT OF PEDAL
1) BRAKE PEDAL
(1) Pedal height from floor plate adjust with
stopper bolt.
140~145mm
ÂPedal height : 140~145mm (5.5~5.7in)
(2) Play
Adjust with rod of mast cylinder.
ÂPedal play : 8~12mm (0.3~0.5in) Floor plate
22B7BS07
4-7
--- Page 10 ---
4. STEERING AXLE
1) Structure
1-49 1-39
1-46 1-16
1-39
1-6 1-40
1-7 1-10
1-48 1-31 1-32
1-8
1-9
1-2 1-5
1-41 3
1-1
2
1-10 1-37
1-35 1-9
1-4 1-7 1-5
1-6
1-41 1-29
1-28
1-28
1-38 1-29
1-41
1-31
1-24 1-26
1-10 1-33
1-32
3 1-34 1-23
2 1-22
1-16 1-21
1-24 1-27 1-36
1-10 1-33
1-30 1-13
1-3 1-11
1-39
1-35
1-4
1-25
1-13 1-12 1-15
1-47
1-18
1-17 1-45 1-14
1-19
1-20
22B7SS06
1-1 Steering axle body 1-17 Hub 1-33 Thrust washer
1-2 Knuckle-RH 1-18 Hub bolt 1-34 Pin
1-3 Knuckle-LH 1-19 Hub nut 1-35 Spring washer
1-4 Bolt 1-20 Hub cap 1-36 Hardened washer
1-5 King pin 1-21 Steering link 1-37 Upper cover
1-6 Taper roller bearing 1-22 Steering cylinder assy 1-38 Lower cover
1-7 Oil seal 1-23 SPH plain bearing 1-39 Hex bolt
1-8 Snap ring 1-24 Steering link pin 1-40 Spring washer
1-9 Collar 1-25 Plain washer 1-41 Shim
1-10 Grease nipple 1-26 Grease nipple 1-45 Taper roller bearing
1-11 Oil seal 1-27 Lock plate 1-46 Potentiometer assy
1-12 Taper roller bearing 1-28 Hex bolt 1-47 Split pin
1-13 Split pin 1-29 Hex nut 1-48 Cover
1-14 Slotted nut 1-30 Hex bolt 1-49 W/Washer bolt
1-15 Washer 1-31 Trunnion block 2 Hex bolt
1-16 Plate 1-32 Bushing 3 Hardened washer
5-8
--- Page 11 ---
(9) Take care to keep the cross pin in the
sleeve and spool horizontal. The pin can
be seen through the open end of the
spool. Press the spool inwards and the
sleeve, ring, bearing races and thrust
bearing will be pushed out of the housing
together.
5-73(4)
(10) Take ring, bearing races and thrust
bearing from sleeve and spool. The outer
(Thin) bearing race can sometimes "stick"
in the housing, therefore check that it has
come out.
5-74(1)
(11) Press out the cross pin. Use the special
screw from the end cover.
5-74(2)
ö A small mark has been made with a
pumice stone on both spool and sleeve
close to one of the slots for the neutral
position springs(See drawing).
If the mark is not visible, remember to
leave a mark of your own on sleeve and
spool before the neutral position springs
are disassembled.
5-74(3)
5-18
--- Page 12 ---
(25) Place the cardan shaft as shown - so that
it is held in position by the mounting fork.
5-83(1)
(26) Grease the two O-rings with mineral oil
approx. viscosity 500 cSt at 20ä C and
place them in the two grooves in the gear
rim. Fit the gearwheel and rim on the
cardan shaft.
5-83(2)
(27) Important
Fit the gearwheel(Rotor) and cardan shaft
so that a tooth base in the rotor is
positioned in relation to the shaft slot as
shown.
Turn the gear rim so that the seven
through holes match the holes in the
housing.
5-83(3)
(28) Fit the spacer, if any.
5-83(4)
5-28
--- Page 13 ---
SECTION 6 HYDRAULIC SYSTEM
Group 1 Structure and function - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
Group 2 Operational checks and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-16
Group 3 Disassembly and assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-20
--- Page 15 ---
4) LIFT SECTION
(1) Operation
The lift section has a single work port to direct flow to the lift cylinder. Only one work port is used,
because the lift cylinder is single-acting(gravity returns the mast to the lowered position).
The lift section also contains part of the components which comprise the safety features. There is
a lift lock check valve. At the neutral position, pressures in the lock valve are equalized across the
lift lock poppet. In this manner, the spring bias keeps the lift lock valve closed and prevents
lowering of the mast.
Η Lifting
When the operator shifts the lever backwards, the spool is extended out of the valve, and this
opens the internal fluid passages that lift the mast. Oil flows through the high pressure parallel
cavity, past the load check valve, through the spool metering notches, past the lift lock check
valve, and to the head side of the lift cylinder.
LIFT
Lift lock
valve
1A
22B7HS11
Θ Lowering
When the seated operator shifts the lever forwards, the spool retracts into the valve, and the oil is
directed from the cylinder, past the lift lock check valve, past the spool metering notches, and to
the common tank cavity.
LIFT
Lift lock
valve
1A
22B7HS12
Pressure is limited by the main relief valve.
6-10
--- Page 16 ---
GROUP 3 DISASSEMBLY AND ASSEMBLY
1. HYDRAULIC GEAR PUMP
1) DISASSEMBLY
(1) Clean the pump externally with care.
22B7HS30
(2) Loosen and remove the clamp bolts.
Coat the sharp edges of the drive shaft
with adhesive tape and smear a clean
grease on the shaft end extension to
avoid any damaging lip of the shaft seal
when removing the mounting flange.
22B7HS31
(3) Remove the mounting flange taking care
to keep the flange as straight as possible
during removal.
If mounting flange is stuck, tap around
the edge with rubber mallet in order to
break away from the body.
※ Ensure that while removing mounting
flange, shaft and other components
remain position.
22B7HS32
6-20
--- Page 17 ---
Lift lock check valve
4.5~5.0 kgf.m
Plug (32.5~36.2 lbf.ft)
4.5~5.0 kgf.m Load check valve
(32.5~36.2 lbf.ft) 3.5~4.0 kgf.m
S
Y (25.3~30 lbf.ft)
S
A
L
O
O
P
S
X
U
Y
A
S
S
A
L
O
O
P
S
X
U
Y
A
S
S
A
L
O
O
P
S
T
IL
Y
T
S
S
A
L
O
O
P
S
Dust wiper Seal
T
F
LI
Main relief valve
4.5~5.0 kgf.m
(32.5~36.2 lbf.ft)
Seal plate
Cap
Bolt : M6X1.0 Bolt : M6X1.0
1.0~1.5 kgf.m 1.0~1.5 kgf.m Secondary main relief valve
(7.2~10.8 lbf .ft) 4.5~5.0 kgf.m
(7.2~10.8 lbf .ft) (32.5~36.2 lbf.ft)
22B7HS25
(6) Auxiliary section
※ Same procedure for all aux sections, but spool assembly components may vary.
① The spool assembly should already consist of the proper aux spool, the return spring, one spring
seat on either end of the spring, the seal plate, a spool seal, and a dust wiper. All of these are
assembled on the end of the spool opposite the clevis.
② Insert the clevis end of the spool into the right-hand side of the spool bore(the tallest end of the
housing). Place the spool cap over the spool and spring assembly and connect the cap to the
housing using two bolts. Torque both bolts alternatively until a torque of 1.0~1.5kgf·m
(7.2~10.8lbf·ft) is reached on both bolts.
③ Install the second spool seal and dust wiper over the clevis end of the spool and retain with a
seal plate and two bolts. Torque both bolts alternatively until a torque of
1.0~1.5kgf·m(7.2~10.8lbf·ft) is reached on both bolts.
④ The load check assembly is inserted into the top center cavity. Torque to 3.5~4.0kgf·m
(25.3~30lbf·ft).
(7) Outlet section
① Install the secondary main relief valve into the cavity on the clevis end of the housing.
Torque to 4.5~5.0kgf·m(32.5~36.2lbf·ft)
6-30
--- Page 18 ---
2. BATTERY
1) STRUCTURE
3 1
2
4
Protective tube
6 5
8
7,9,10,11
20B7EL03
1 Cells 7 Plug
2 Steel box 8 Spacer
3 Cell connector 9 Handle (Red)
4 Row connector 10 Screw
5 Positive leading cable 11 Spring washer
6 Negative leading cable
7-4
--- Page 19 ---
4. PUMP MOTOR
1) STRUCTURE
4
5
6
12
3
15 13
16
14
1
2
10
9
11
7
8
22B7EL08
1 Rotor 7 End shield drive end 12 Screw
2 Stator 8 Oil seal 13 End shield non drive end
3 Terminal 9 Ball bearing 14 Sensor bearing
4 Screw 10 Locking ring 15 Spring washer
5 Hexagon nut 11 Locking ring 16 O-ring
6 Crinkle washer
7-14
--- Page 20 ---
4) FUNCTION CONFIGURATION
ÿ TRACTION CONTROLLER-MASTER
Using the CONFIG MENU of the programming console, the user can configure the following
functions (see "OPERATIONAL FEATURE" chapter for an explanation of "hydraulic steering
function") :
(1) Submenu "SET OPTIONS"
Η Hour counter
- RUNNING : The counter registers travel time only.
- KEY ON : The counter registers when the "key" switch is closed.
Θ Battery check
- ON : The battery discharge level check is carried out; when the battery level reaches 10%, an
alarm is signalled and the maximum current is reduced to the half of the programmed
value.
- OFF : The battery discharge level check is carried out but no alarm is signalled.
Ι Traction cutout
When the alarm "BATTERY LOW" appears, if this option is programmed to ON the traction
maximum speed is reduced to 60Hz.
Κ Lift cutout
When the alarm "BATTERY LOW" appears, if this option is programmed to ON the lift function is
disabled.
Λ S.R.O.
If this option is set to on the static return to off is requested for starting the truck. The required
sequence is :
ÂSeat-direction lever-accelerator pedal or :
ÂSeat-accelerator pedal-direction lever within the seq. delay time
If this option is set to off the required sequence to start the truck is :
ÂDirection lever-accelerator pedal or :
ÂAccelerator pedal-direction lever within the seq. delay time
Μ Hydro key on
- ON / OFF : If this option is programmed ON the traction inverter manages an hydraulic steering
function when the "key" is switched ON.
Ν Stop on ramp