Technical Training Guide

25-30D-35DN-9V
v1.2

24/02/2022 Raymond Galavazi - A/S Service MH

Hyundai Construction Equipment Europe
This publication is intended to support
Hyundai dealers on Hyundai products.
All other use, including reproduction
and distribution outside of the Hyundai
dealer network, is strictly not allowed
without prior written consent of HHIE.
General Machine Introductions 4

Transmission 8

Front axle & Brake system - Rear axle 23

Hydraulics 35
I. Steering System 36
II. Main Hydraulics 39
Electrics 51

Engine 118

Aftertreatment 144

Diagnostic Tool 161

Maintenance 172

VCU DTC Codes 178

General machine introduction
General machine introduction

Engine :
HMC D4HB 2.2 – 47,8Kw/2300RPM
(Hyundai)
Fuel consumption (VDI60) :
• 25D-9V: 2,7 l/h
• 30D-9V: 3,0 l/h
• 35DN-9V: 3,2 l/h
Travel speed:
16,4km/h – 18,8km/h (unloaded)
Emission regulation :
Stage V – CO2 = 750,4g/kWh
Max Torque:
24,1kg-m / 1600 rpm

5
General machine introduction

6
General machine introduction

1 Mast
2 Lift cylinder
3 Steering unit
4 Control valve
5 Tilt cylinder
6 Fork
7 Front wheel
8 Drive axle
9 Hydraulic pump
10 Transmission
11 Torque converter
12 Engine
13 Air cleaner
14 Exhaust pipe
15 Steering axle
16 Steering cylinder
17 Rear wheel
18 Radiator
19 DPF assy.
20 Silencer
21 Overhead guard
22 Seat
23 Control lever
24 Steering wheel
25 Drive shaft

7
Transmission

F30
Smart
Transmission – Basic data

4
3

1. Hand Brake 5
2. Oil Filter
3. Oil Dip Stick
4. TCV 7
5. FWD-REV solenoids + Handbrake Solenoid
6. Output
7. Speed Sensor
8. PTO
8
6
1
9
Transmission Main Hydraulics

3 1. Charging Pump
2. Oil filter
8 3. Main relief valve
2 4. Parking brake
4 electro valve
5. Torque Convertor
6. Forward Clutch F1
1 5 7. Reverse Clutch R1
8. F1/R1 proportional
solenoid
6 9. TC relief valve
7

10
Torque Convertor
A torque converter is a type of fluid coupling, which allows the engine to spin somewhat
independently of the transmission. If the engine is turning slowly, such as when the machine is
idling, the amount of torque passed through the torque converter is very small, so keeping the
machine still requires only a light pressure on the brake pedal. If you were to step on the gas
pedal while the machine is stopped, you would have to press harder on the brake to keep the
car from moving. This is because when you step on the gas, the engine speeds up and pumps
more fluid into the torque converter, causing more torque to be transmitted to the wheels.
Converter can be tested in 2 ways:
A. Inlet – Outlet pressure test
B. Stall test: If the converter is working, engine RPM will drop under load conditions at full
acceleration

The stator sends the fluid

Pump is not mounted on The torque converter turbine:
the TC Note the spline in the middle.
This is where it connects to the
transmission.
returning from the turbine to
the pump. This improves the Flex plate
efficiency of the torque
converter. Note the spline,
which is connected to a one- Torque Convertor (TC)
way clutch inside the stator.

11
Torque Convertor TC In pressure relief valve
Oil temp must be 50°C-60°C
To TCV
Engine RPM TC IN (MPa) TC Out (Mpa)
2400 0,3 - 0,7 0,2 – 0,4
Stall : 1800-2000RPM
Main relief valve

lubrication

12
Transmission

13
Transmission Clutch Pack - Forward

Main Line

Lubrication

1. Clutch packs
2. Pistons

14
Transmission Clutch Pack - Reverse

Main Line

Lubrication

2
1. Pistons
2. Clutch packs
15
Transmission – Control valve layout

1. Main relief valve 6. REV Pressure Check Point

2. Parking Brake Solenoid
3. FWD EPPR Valve
4. REV EPPR Valve
5. FWD Pressure Check point
7. Hand Brake Pressure Check Port
8. Main pressure Check Port
9. Hand Brake OUT Port
4 3
10. Pressure/Temp Sensor

16
Transmission – Control valve hydraulics

800 RPM (Mpa) 2400 RPM (Mpa)

Main 1.2 +- 0.2 1.2 +- 0.2
Forward (F1-F2)
1.2 +- 0.2 1.2 +- 0.2
Reverse (R1)
Oil temp must be 50°C-60°C

17
Inching pedal
1st stage = inching
2nd stage = full inching + service brake
Inching sensor
Connected to TCU

18
Transmission - TCU

19
Transmission – TCU electrical diagram

20
Transmission – TCU Error Code List

21
TCU Update
Please follow the detailed instructions and
required files on the Dealer Portal/Service/
Training/Machine Software files MH / TCU
TCU Update - Tools

Laptop WIN10 Update cable

PEAK CAN interface 2YFJ-15110

23
Front axle & Brake system
Rear axle

HCM
Front Axle - Structure

1. Pinion shaft
2. Ring Gear
3. Differential
4. Axle Shaft
5. Hub
6. Service Brakes

Full instructions are available in the Service Manual 25

Front Axle – Final Drive (L+R)

Ring Gear
Service Brakes

Planet Gear
Carrier

Planet Gear

Sun Gear

Wheel studs

Full instructions are available in the Service Manual 26

Drive axle - oil

Oil plug
Oil plug 42~52 N-m
Main Oil plug

Always check level

Oil change
Initial : 100Hrs Make sure air breathers
Approx. 8,2L Periodic : are not clogged
1000Hrs-1/year cover before power wash off axle
Shell SPIRAX S4 XTM

27
Brake system – General Hydraulics
Main Brake valve
Service brake pressure switch
(ON/OFF) Service brake fluid
AZOLLA ZS32 (Hydraulic oil, ISO
VG32)

Service brake
main line

Hand brake pressure switch (ON/OFF)

Hand brake line

ATF DEXRON III

±12Bar
Service brake lines

28
Parking Brake (in T/M)
FWD/REV Clutch Pressure : ±12Bar
Minimum opening pressure : ±10Bar
Torque Convertor

Pressure check point

PB

PB
PB

29
Parking Brake (in T/M)

Brake switch
Soak in oil for 24H
before installing
(T/M Oil)

Clutch pack

Clutch Pack
Hydraulic supply
(coming from TCV)
Return Springs

Item Standard Limit

Friction Disc t=2.0 t=1.7

Plate t=1.4 t=1.2

Piston & Seals

Full instructions are available in the Service Manual 30

Parking Brake (In T/M)
Emergency release procedure

1
Piston Seals

Clutch pack Piston

Remove plug 2
Return
Springs

Emergency Remove T/M

release case bolt
(M10-30L)
Insert into
parking brake
assembly
3
Fasten bolt clockwise until
parking brake is released

31
Front Axle – Service brakes

1 Brake pedal
2 Inching pedal
3 Inching sensor AZOLLA ZS32
4 Brake fluid tank (Hydraulic oil, ISO
VG32)
5 Brake valve

32
Front Axle – Service brakes
Clutch Pack
Seals
Actuator
Brake piston
Piston
Return springs
+ bolts Actuator

Return Spring

+- 1mm distance
Clutch pack between actuator
& bolt

Item Standard Limit

Friction Disc t=2.5 t=2.2

Soak in oil for 24H
before installing
Shell SPIRAX S4 XTM Plate t=2.5 t=2.2
33
Rear Axle

176Nm ±19Nm

34
Rear Axle

35
 Hydraulics
I. Steering System
II. Main Hydraulics
I. Steering System
Steering system

Turning Left-Right

Manual steering check valve

38
Priority Valve
Main pressure

Tank 1 Plug
2 O-ring
LS orbitrol 3 Plug
4 Screw-seat
5 O-ring
MCV Orbitrol 6 Seat-spring
7 Spring
8 Seat-valve
9 Poppet
10 Sleeve
11 Filter
12 Housing
13 Spring
14 Spool
15 O-ring
16 Plug
17 Orifice
18 Orifice

39
II. Main Hydraulics
II. Main Hydraulic Lines

41
Hydraulics – Manual MCV

1. Hydraulic pump
2. MCV 11
3. Priority valve 4
4. Orbitrol
5. PF Valve (Forced pressure) 10
12
6. Return filter 13
7. Main relief valve
8. Second relief valve
9. Hydrostat valve 5
10. Load sensor
9
11. Down safety valve
12. Pilot load holding check
valve
13. Down control valve
14. Cut-Off solenoid (OPSS) 2
15. Main pressure & temp
sensor 6 8
16. Tank breather 3 7 14

1 15

16
42
Hydraulics – Manual MCV

Lifting Lowering

43
Hydraulics – Manual MCV

Tilting FWD Tilting Back

44
MCV Structure – Manual

Max 1,5 turn

Tightening torque max 2.5Nm

Tilt over center valve

45
Main Hydraulic diagram -Fingertips
1. MCV
2. Main relief valve
3. Second relief valve
4. Hydrostat valve 11
5. Load sensor
6. Down safety valve 6
7. Down control valve
8. Cut-Off solenoid (OPSS) 5 9
9. Tilt Lock Valve 13
7
10. Lowering Lock Valve
11. Orbitrol
12. Priority Valve
13. PF Valve
10
14. Return filter
15. Breather 8
12

Relief pressures 1
25D-9V
4 3
DV1 : 175 ± 3Bar – DV2 : 140 ± 3Bar 14 2
30-35D(N)-9V
DV1 : 200 ± 3Bar 2 – DV2 : 140 ± 3Bar 15

46
Hydraulics - Fingertips

Lifting Lowering

47
Hydraulics - Fingertips

Tilt FWD
48
Hydraulics - Fingertips

Aux1
49
MCV Structure – Fingertips

Max 1,5 turn

Tightening torque max 2.5Nm

Alan Key #3
Max 2.7Nm
Sealed

50
PF Valve – Forced pressure valve

SV1 is controlled by
MCU
Valves will be
commanded when
needed to assist
during auto
regeneration – DPF
cleaning

Hydraulic functions are

available when PF valve
function is active but will be
slightly influenced.
Higher engine noise due to
extra engine load.

51
Electrics
Electrics – General component Location
New Cluster
(display + MCU)

EU STD

53
Electrics – General component Location
Cluster/MCU

(Opt)

Parking brake switch

Airco control unit

1. TCU
2. Warning Buzzer
3. Power relay
4. Flasher Unit

54
Electrics – New Cluster
Fuel level
Display rear
camera view Time & date

Speed meter

UP

Navigation buttons
DOWN
Coolant
temperature
ENTER

ESC

Front/rear tilt – Load weight – Operating Hours – mileage – Left/right tilt

55
Cluster - Icons

Indication lamps
Warning lamps

56
Cluster - Menu

Exception

Protected access
Service password or
engineering
password required

Open access

Standard Service Password : 00000 → change before delivery !! 57

Cluster - Equipment
Protected by different service password
98282

Chose the model

you have in this list

Wrong model selection can cause no or bad truck operations

59
Cluster – Tilt setting

Truck conditions
• Tilt Sensor installed
• Truck on level floor
• Key ON
• Mast in vertical position
Initialized
No sensor and/or not initialized Red Tilt warning Red Tilt warning
Full Stop : +-3.4° Full Stop : +-2.3°
While driving : 25-30D : +-20.8° --- 35DN : +-24.2° While driving : +-10.2°

60
Cluster – Weight indicator settings 1/2

61
Cluster – Weight indicator settings 2/2
1

Use a weight nearest to the max capacity of the truck for a more
Initialization erases all previous
precise measurement
weight indicator settings (EX
[Make sure the load is ready to be lifted before proceeding to
cross section settings)
next step]

62
Cluster – ESL (Engine Start Limit)

Activate or deactivate
ESL function

Becomes active after

KEY OFF
After activation you can
start engine within
10sec after KEY OFF –
after 10sec password
needed

Password change through

Within the chosen time
display settings
frame you don’t need to
enter a password to restart
the engine.

ESL time count resets after every engine OFF-ON

ESL Password can be overruled by Service password

63
Cluster - Camera

ON : camera image will be shown on cluster when shifting to reverse

OFF : image will only be shown when pushing the “camera button” on the cluster

64
Cluster – DSCR

DSCR
Blocks shifting FWD/REV according to set speeds

Avoid transmission shocks and weel spin

Gear shift request

FWD to REV

ON/OFF FWD

5km/h
Transmission
in NEUTRAL

3km/h
REV

Gear shift FWD to REV

Logic works in FWD to REV and REV to FWD

65
Cluster – HAC Hill assist
HAC Setting
Activate/de-activate Hill assist When activate the handbrake will be automatically activated when stopping
option (brake/inching pedal) on a ramp

66
Cluster – Speed limit
Speed Limit - Sets truck max speed

MAX Speed

Speed limit possible between

8km/h - 15km/h

67
Cluster – ZERO Start

ZERO Start – Activate/de-activate

De-activated : traction is activated after selecting FWD or REV

Activated : traction will not be activated on gear select, but after pressing acc pedal

68
Cluster – CSC : Creep Speed Control

CSC – Activate/de-activate

When Zero Start is OFF AND selecting a direction AND :

- CSC if OFF → machine drives off to +/- 5km/h
- CSC is ON → machine drives off to a programmable (in TCU calibration menu)
speed between 1,8 And 2,2km/h

If the creep speed is over 2.2km/h

Settings range : → Adjust Min. current by -10mA or -20mA
• Default : FWD/REV 350 ~ 380mA If the creep speed is lower than 1.8km/h
• Up: +10mA, +20mA → Adjust Min. current by +10mA or +20mA
• Down: -10mA, -20mA → Or adjust Max. current by +10mA or +20mA

69
Cluster – Clutch Protection Alarm
Clutch Protection Alarm – Activate/de-activate

When slipping off the clutch is detected during driving, or when clutch pressure is too low,
for more then 3 seconds a buzzer will warn the driver.
In most cases driver error : keeping the foot on the inching pedal.

Buzzer
3 seconds

70
Cluster – TCU Calibration – Inching Sensor Setting

Standard settings should be OK – Only change settings if the customer complaints he’s getting error code during normal inching
By changing the parameter you change the inching sensitivity

Only the minimum valve current value can be changed

Settings range :
920mA: Clutch Max. Current
Current [mA]

▶ Default: 0mA
▶ Up: +10mA, +20mA
▶ Down: -10mA, -20mA 400mA: Inching Max. Current

340mA Exaggerated view

Inching Min. Current

Start End

71
Cluster – TCU Calibration – Shift Profile FWD/REV separately

Standard settings should be OK – Only change settings if the customer complaints off shock

Shock instantly at drive off : decrease oil flow → -10mA or -20mA

Shock after drive off : increase oil flow → +10mA or +20mA
Settings range :

▶ Default: 0mA
▶ Up: +10mA, +20mA
▶ Down: -10mA, -20mA

72
Cluster – Seat Belt Interlock
Set Belt Interlock – Activate/de-activate

If SBI system is activated it works together with the OPSS function → if activated the driver will need to put on
his seat belt before he can start and/or operate the forklift

If ESL is activated the seatbelt must be put on before entering the ESL password,

Programming info
• In case the seat belt switch is not installed this option will not be shown in the cluster
• If the seat belt switch is installed but de-activated and you want to activate the option you have to put the
seat belt on before entering the service menu. If the MCU doesn’t see the seat belt switch signal he will not
show this option in the menu

73
Fingertip setting 1/2

74
Fingertip setting 2/2

75
Cluster – Cluster-Ci Info

76
Cluster – ECU/TCU/VCU failure data

Active Error codes

Historical Error codes

Short explanation on selected error code

Only deletes history in Cluster

Failure history stay in ECU memory

ECU DTC codes → EngineDiagnosticManual – TCU DTC Codes → pg21 – VCU DTC Codes → pg174 78
Cluster – Maintenance Management

Change interval

Reset interval

79
Cluster - Monitoring

Check all analog signals

Check all digital signals
Pressures, temperatures,
Like switches ON/OFF
voltages, ..

80
Cluster – User password change (service password)

Standard password : 00000

Changing this password before delivery to customer is recommendable !!

If you forget the password only engineering password can overrule

(on special request to AS HCEE)

81
Cluster – Display settings

No password – menu available for driver

83
Cluster/MCU Update
Please follow the detailed instructions and
required files on the Dealer Portal/Service/
Training/Machine Software files MH /
Cluster
Cluster/MCU Update - Tools

Update cable
Laptop WIN10 USB to serial 2YFJ-15110

85
Electrical diagrams

Check the service manual

Electrics – Starting Circuit

87
Electrics – Fuel warmer circuit & WIF sensor

Switch + heater

Fuel heater
Thermo switch [CN-151 (2)] I/conn [CN-2 (10)] Fuel warmer relay [CR-26 (86)]
Fuse box [CN-37 (No.2)] I/conn [CN-2 (6)] Fuel warmer relay [CR-26 (30 → 87)]
I/conn [CN-2 (11)] Fuel filter-heater [CD-38]

88
Electrics – PFValve (Forced pressure valve)

89
Electrics – Connector number

All connector information

is available in the service
manual

• CN = Connector
• CR = Relay
• CS = Switch
• CD = sensor
• CL = Lamp
• DO = Diode

90
Engine

Complete Workshop manual available on the portal

General specifications

92
Engine Mechanics 1. Drive Belt
2. Cooling fan bracket
3. Idler
Alternator
4. Plug
5. Crank pulley A
6. Crank pulley B
2 3
7. Tensioner bracket
8. Tensioner
9. Timing chain cover
10. Front oil seal

Waterpump 8

93
Engine Mechanics

1. Camshaft chain
sprocket
2. Timing Chain “B”
3. Timing chain “B”
guide
4. Timing chain “B”
tensioner lever
5. HPPump chain
sprocket
6. Timing chain “B”
auto tensioner
7. Timing chain “A”
auto tensioner
8. Timing chain “A”
tensioner lever
9. Timing chain “A”
10. Timing chain “A”
guide
11. Crankshaft chain
sprocket

Detailed instructions for engine rebuild -> EngineWorkshopManual 94

General overview

95
Engine control Unit
CAN Convertor MCU
INPUT OUTPUT

96
ECU Input Sensors
Connector
Camshaft position sensor (CMPS) Cranckshaft position sensor (CKPS)

Hall sensor type

- Magnetic encoder
- Installation on the rear oil seal of crankshaft

If one fails during operation Work together to

the other takes over but determine fuel injection
engine restart will not be (quantity and timing)
possible • Ignition switch "ON" & Engine "OFF"
• Voltage is measured on wiring side(
Disconnected)
Only disconnect when B- is disconnected 97
ECU Input Sensors
Barometric Pressure Sensor (BPS)

ECM

Fuel rail

Barometric Pressure Sensor is in the ECM. It detects

barometric pressure around the equipment. And it is
important part to correct fuel injection quantity by difference
of air density and control EGR.
Air intake manifold

Atmospheric pressure
Boost Pressure Sensor (BPS)

In combination with the data received

from MAF sensor, air intake temp the
position off the EGR valve and WGT • Ignition switch "ON" & Engine "OFF"
(Turbo) solenoid valve will be determined. • Voltage is measured on wiring side
Pressure to high = engine derate

98
 Glow relay unit transmits a feedback after diagnosing the glow
Glow system system (12V – OK, 1.5V – NG)
MCU

1 Glow Plug 4 Glow signal to MCU 7 Glow plug condition signal

2 Glow control module 5 Battery + Connection 8 Injector
• Step-1 (quick heating mode) : When IG
3 Key switch 6 Glow activate signal
ON, control pre-heating by coolant
temperature to enhance starting
performance
When battery voltage is over
Signal ECM to GCM 11.5V → duty control, under 11.5V →
100% duty
Signal GCM to GP • Step-2 (keeping warm mode) : When
starting the engine, duty control to
keep the glow plug temperature
1000℃ 0,55Ω
• Step-3 (post glow) : duty control under
max 1,100℃ in consideration of cooling
of the plug after starting (180-300s –
stable idling + emission reduction)

99
Fuel system – General layout
FTS [NTC thermistor]
Protects fuel system parts against damages (Rapid
deterioration by vapor lock/oil membrane
destruction) caused by to high fuel temp (>80°C) 2000Bar
Temp ↗ = sensor voltage ↘
Sensor voltage below 172mV for more then 1sec =
engine derate (DTC P018200)
PRV

NRV
Non-Return-Valve

WIF

100
Fuel system RPS signal goes to ECM, used for :
• control correct injection amount and timing.
• adjusts rail pressure with the rail pressure regulator valve (calculates pressure ≠ RPS value)
• Value out off range DTC P019100

Fail = new rail

Rail Pressure Sensor (RPS)
Rail Pressure Regulator
Fail = new rail

Inlet metering valve (Fuel Pressure Control Valve):

Controls quantity of fuel coming from low pressure
fuel pump into high pressure fuel pump, Controlled by
ECM. Negative type,
Rail pressure Regulator Valve (RPRV) :
Electrical controlled pressure relief valve. Controlled
by the ECM in combination with the rail pressure
sensor depending on engine fuel needs.
Negative valve type meaning that if there is a failure
the valve stays open and returns the fuel coming from
the HP directly to the tank,
Rail pressure sensor :
Provides pressure readings from the rail to ECM

101
Fuel system – HP Pump & FPCV (SCV)
FPCV E
Return
Low Pressure C
Fuel IN (4,5Bar) M 1 2
Negative type

3
4 5

Fail = new HPpump

Fuel Pressure Control Valve

1. Valve body
2. Solenoid
3. Valve spring
4. Needle valve
5. Amateur
Detailed instructions -> EngineWorkshopManual 102
Fuel system – Low pressure pump & fuel filter

ECM detects engine RPM -> relay -> pump (not at IG ON)

OUT Thermo Switch

Return

Power terminals
Fuel Heater

Thermo switch :
Bi-metal switch – switches the fuel heater
ON/OFF
ON : -3±3°C – OFF : +5±5°C IN
Fuel heater : OUT
Heats the fuel through a PTC element
Filter Element :
+90% water separation – filters all foreign
substance -4µmm (99,6%)
pump pressure ±4.5 bar. WIF Sensor :
Flow : 148 ~ 200LPH Detects presence of water in the fuel.
(13V, 450kPa, 8.5A) Warning signal on the cluster, Signal to
ECM for engine derate. Separation capacity
±58±5CC

103
Fuel System - Injectors
Injector return lines

Factory
installed

Turn lock 90°

counter Clock
When swapping/replacing injectors you must
change the trim codes with G-scan diagnostic tool

Self learning injector trim

When white
Every +-1000km an injector trim adjustment
“gears” are
is carried out during +-300km by the ECM
towards outside
Trim adjustment is measured during
lock is open
deceleration and injection stop, Small
Pull connection
amount of fuel is injected and measured
upwards
through engine speed pick up,

Detailed instructions -> EngineWorkshopManual 104

Intake/exhaust – General parts

ACV
(Air Control Valve)

Intercooler
MAFS
(Mass Air Flow Sensor)

EGR Cooler

EGR

WGT
(Waste Gate Turbo)

105
Intake components
Mass Air Flow Sensor (MAFS)

MAFS is a digital sensor.

Sends air flow mass &
temp data to ECM, Temp =
Voltage, MAF = frequency
(Hz)
ECM performs EGR
system feed back control
with the information of
measured mass air flow.

Detailed instructions -> EngineWorkshopManual 106

Intake components Air Control Valve
(ACV [Backpressure valve])

Normal open valve

type. ECM
controlled valve,
Valve position by
PWM, controlled DC
motor, return spring
for normal open
position after key
OFF, position sensor
-> feedback to ECM
mounted on throttle body

- anti-judder : at engine off valve closes ->

no air in intake -> reduce vibrations
- DPF Regeneration : ECM partially closes
valve -> exhaust temp. Rises
- Assistance in EGR function : exhaust
pressure ≤ intake (exhaust gas can’t reach
intake) -> valve partially closed -> intake
pressure < exhaust pressure (more air
from exhaust to intake manifold)

Detailed instructions -> EngineWorkshopManual 107

EGR Controlled by ECM - MAFS data used

1-2 Exhaust IN-OUT

3-4 Coolant IN-OUT

Detailed instructions -> EngineWorkshopManual 108

WGT (Wastegate Turbo)

109
Engine – Lubrication - Oil flow

110
Engine – Lubrication

Drain plug
Tightening Torque: 3.5 ~ 4.0kgf.m

Oil Filter
Tightening Torque: 1.0 ~ 2.0kgf.m

Detailed instructions -> EngineWorkshopManual 111

Engine - Lubrication
Oil Pressure Switch
Normal closed switch
Switch opens at 0,5Bar

EGR Cooler

Tightening torque : 14,7-21,5Nm

Always apply seal lock TB2403

Detailed instructions -> EngineWorkshopManual 112

Engine - Cooling
Thermostat OUT Coolant concentration :
Heater Water/Ethylene glycol
50/50

amine compounds, silicic

acid compounds, boric
R acid compounds, nitrite
compounds
Bypass a
d
EGR Cooler
i
a
t
o
r
EGR Valve Waterpump
IN

113
Engine – Cooling - Heater

Thermostat
Heater

Bypass
EGR Cooler

EGR Valve Waterpump

IN

114
Engine - Cooling
Coolant temperature sensor

Measure between negative & signal wire

installed on the thermostat housing assy as
Supply : 5V
negative temperature coefficient, Coolant temp, reading used by
ECM for controlling fuel injection quantity, cold start, fan control,

In case coolant temperature sensor is broken, ECM uses

standard values during operation and cranking,
Running : 80°C – Cranking : -10°C

Detailed instructions -> EngineWorkshopManual 115

Engine - Cooling

Install thermostat with the jiggle valve(A) upward.

Thermostat

Outlet fitting Gasket

Full opening temperature: 95℃

Valve lift : 10mm @ 95°C

Detailed instructions -> EngineWorkshopManual 116

Aftertreatment
DOC+DPF
DOC + DPF General
Differential pressure sensor

Temp. Sensor T (DOC OUT/DPF IN)

OUT
Temp. Sensor T4 (DOC IN)

OUT Gasket+clamp
IN Gasket+clamp

DPF Gasket+clamp
DOC

IN

118
DOC General
MAT
Housing Assist in temp rise for
DPF function

Convert harmful carbon

monoxide and
hydrocarbons in exhaust
gas into harmless
Filter carbon dioxide and
water by oxidation
Silicon Carbide (SiC)

119
DPF General

Trap PM

• honeycomb structure to create more surface area.

• a lot of small holes on the wall.
• made from Silicon Carbide.
• covered with catalyst which react with PM during regeneration.

Inside DPF

• The soot collected inside the DPF is mainly a carbon component.

• The process in which carbon compounds react with oxygen or nitrogen dioxide and become other by-
products.
• The non-oxidant substances among the soot components remain inside the DPF as ashes, which do not
disappear through regeneration.

Ash cleaning around ±3000Khrs (depending on application)

120
DPF General

Regeneration

Thanks to catalyst on DPF,

PM can combine with 𝑂2 in exhaust gas to form 𝐶𝑂2 at 600 ℃.
𝐶𝑂2 is so small that get out through holes of DPF wall.

Regeneration is a process to change PM into CO2 by chemical reaction (catalytic reaction) in order to
restore filtering function without replacement.

121
Regeneration
ACV

• The extra injected fuel

• If T4 is to low for during post injection will
auto regeneration create chemical reaction
the ECM will inside DOC to increase
active the PF valve t°↗ ≥300°C ≥650°C T5 temperature
to increase stress
on engine T4 T5
• During parked
regeneration the
ECM commands
the air control
valve (back
pressure valve) to
DOC DPF
decrease air flow
to obtain different
air-fuel mixture.

122
Regeneration Power derate : 29~36% @1,200~2,000rpm

tmax=30Hr tmax=1,5Hr tmax=1,5Hr tmax=1,5Hr

No auto regeneration
No parked regeneration
Auto regen Only parked Engine check lamp ON
Normal Auto regen or regen Power derate
during
operating parked regen Engine check
operating
conditions request lamp ON – Regen only possible with
conditions power derate service tool G-SCAN

123
DPF Soot Levels compared to status
Operation Time Soot g
Level To improve DP regeneration logic an update for Cluster_Ci and engine
R2.2 - 9V R2.2 - 9V ECU is available.
• Cluster_Ci update : screen logic changed
0 - - • Engine ECU : allowed parked-regen time extended – improved soot
1 30Hrs 30g calculation
2 +1.5Hrs 32.5g
3 +1.5Hrs 35g In case off DPF regen issues perform complete S/W update.
4 +1.5Hrs 37.5g All others at first service interval

+328g EU-SB-202110-009
Model Serial Break Cluster Serial Break for ECU
25D-9V 0089 ~ 0078 ~
30D-9V 0062 ~ 0059 ~
Or replace DPF 35DN-9V 0132 ~ 0114 ~
Soot level after regen <6,1gr

Soot value >328g → G-Scan will inhibit a forced regen request to start
Check “charge state of the partikulate filter” in G-scan monitoring
If one off the set conditions changes status [Parking Off, Gear ≠ N, acc pedal ≠ 0%] during regen you can get a “DPF regen not finished”
notification on the cluster.

124
Regeneration
Inhibit Switch
OFF

Power derate :
29~36%
@
1,200~2,000rpm

Only ON during regeneration

125
Regeneration Inhibit Switch
ON

Power derate :
29~36%
@
1,200~2,000rpm

126
Parked regeneration Operating Conditions
• Drive to safe place (outside building
away from flammable products)
Driver is guided through the display • Parking Brake ‘ON’
how to perform the parked • Gear ‘N’ Step 2
regeneration • Don’t touch accelerator pedal • Pressing parked regeneration switch
• Coolant Temperature > 60℃

Display logic has been changed

with latest Cluster_Ci update
Regen fail will be notified in
screen STEP3

EU-SB-202110-009

Parked regeneration will abort if one of the following conditions changes :

Gear ≠ N – accelerator pedal = ON – parking brake released

127
Forced regeneration

Select Diagnostic

Select forklift model

ECU

OK
128
Forced regeneration

Conditions
must be set or
regeneration
will fail
Values will change during
regeneration process

129
Forced regeneration
In case you see abnormal
values take a screen shot

Parked regeneration can be stopped manually – not advisable

If the parked regeneration fails
you will receive above screen
with a list of reasons why it
failed,

Resolve issues and restart the

parked regeneration request

130
DPF replacement

After DPF replacement

procedure perform a forced
regeneration to initialize
regeneration
131
DPF – Need to know’s for technicians and/or drivers 1/2
1. Position inhibit switch :
a) Explain driver importance off inhibit switch position – if need be disable possibility to activate inhibit function
b) Always check inhibit switch position in case truck goes to Level 4 to quickly

2. Explain to the driver that when the “High exhaust System Temperature” is on an engine shutdown is not allowed to avoid frequent
parked regeneration due to high DPF soot load.

3. When the DPF is in level 4 and the forced regeneration won’t start with G-SCAN tool check the soot amount, If above 328g the
regen process will be blocked and a DPF cleaning or replacement is required,

4. If the parameter “charge state of the particle filter” is abnormal: Differential pressure value learning is required.
1) Turn on the engine
2) Keep the engine at idle rpm over 15min.
3) Turn off the engine.
4) Repeat 2~3times steps 1 → 3

132
DPF – Need to know’s for technicians and/or drivers 2/2
5. Calculation of actual truck running time
• Coverage length is the total km the engine run as of factory (ECM). By dividing the total km by key hours, you know approximate
qty of KM per running hour.
• The drive distance since last regen : in m but actually km (G-Scan software issue). There you can see how many km the truck
drove since last parked regen or forced regen. You then can calculate how many hours it has been.

DTC Code Description

P0420 DOC / Conversion Performance Invalid
P242F DPF / Clogging
P24A2 DPF / Incomplete Regeneration
P2033 T4 sensor DOC inlet / Too High
P2471 T5 sensor DPF inlet / Too High Voltage
P246F T5 temp. sensor mutual error
6. Error codes related to after treatment system : P2455 Differential press. Sensor Too High
P2454 Differential press. Sensor Too Low
P2002 Diff. Pressure Sensor / Tube inverted
P0420 DOC / Conversion Performance Invalid
P226D DPF / missing substrate
P2453 Differential Pressure Sensor performance invalid
P24A4 DPF level 4 reached
P2463 DPF level 3 reached
133
Diagnostic Tool
Diagnostic Tool – G-SCAN2
G-Scan Manual available for download on dealer portal

G-SCAN -> OBD2 cable + KIA20

12HN-00010

Please update your G-Scan tool before starting to use!!

Please follow the instruction manual step by step.
The instruction manual and the required files are on the
dealer portal Service/Training/Machine Software MH/ECU

135
Diagnostic Tool - Connection
1. KEY OFF – G-SCAN OFF
2. Disconnect 1 pin connector ( Only for -9V)
ONLY -9V

2a. Disconnect 1 pins connector

(power supply to CAN module);
Otherwise no connection between G-scan tool
and ECU

You will receive communication error on cluster at Key-on→ “Ignore”

Do NOT forget to reconnect afterward ECU update is completed. (only at

KEY OFF)

136
Diagnostic Tool – Connection ( -9V only)
Check which of the 2 configurations your truck have and then
follow instructions according the version ( Only -9V models)

-9V (Version 1)
-9V (Version 2)
2 Equal square connectors
1 Square connector(KET) and 1 OBD connector
( different pin layout *)

Engine ECU * Engine ECU

Cluster_Ci & TCU * Cluster_Ci & TCU

*identify connector : see next page

137
Addendum : identify machine connector (-9V only)

-9V (Version1) -9V (Version2)

No pins on connector position #1 & #2

= Engine connector

KIA20 Connector OBD Connector

= ECU = Cluster_Ci & TCU

138
Diagnostic Tool

Main Screen

All recorded data and screenshots

(saved on SD Card)

SD card folder
Diagnostics & programming

ECU Upgrade
Always follow the instructions and/or
conditions shown for each function
139
Diagnostic Tool

1 2

Select :
3 4
1. Machine type
2. Manufacture ECU
year
3. Engine model
4. ECU
5. Confirm with OK

5
140
Diagnotic Tool - DTC

This page will show all historical and active engine error codes

141
Diagnostic Tool – Data Analysis

Items of interest can be selected by the round check

box, Checked items move to the top off the list

Data can be shown in a graph and recorded for later analysis

142
Diagnostic Tool – Actuation Test

Engine actuator function can be tested through this menu

Injector shut off test

143
Diagnostic Tool – ECU information

144
Diagnostic Tool – Flight recorder

All recordings made during

monitoring can be found here.

You can play them again for

analysis

145
Diagnostic Tool – Special Function
When replacing/re-positioning
injectors trim codes need to be When replacing certain engine parts the engine data
inserted into the ECU needs to be reset,

Cylinder test

Remove air from fuel system after work on fuel system

(protect Hppump and minimize engine start time)

Forced regeneration and regeneration after DPF

replacement

Check engine tuning data

146
Diagnostic Tool – ECU software upgrade

ECU upgrades will come available

through a service bulletin

Please follow the instruction manual step by step.

The instruction manual and the required files are on the
dealer portal Service/Training/Machine Software MH/ECU

147
Maintenance
Maintenance

New Truck

149
Maintenance – Daily checks

150
Maintenance – Periodic table

151
Maintenance – Periodic table

152
Maintenance – Lubrication Specifications

153
VCU DTC Codes
VCU DTC Codes

155
VCU DTC Codes

156