Model:
20BC-9, 25BC-9, 30BC-9, 32BC-9 Forklift Truck
Product Name:
Hyundai 20/25/30/32BC-9 Forklift Truck Service Repair Workshop Manual
Model Codes:
20BC-9, 25BC-9, 30BC-9, 32BC-9
Target Audience:
Ideal for forklift owners, fleet managers, maintenance personnel, and repair shops working with Hyundai BC-9 series forklifts.
Value Proposition:
Provides essential technical information to maintain, diagnose, and repair these specific Hyundai forklift models, ensuring operational efficiency and longevity.
Readability:
Designed for easy reading, with clear instructions and logical structuring.
Completeness:
Offers all information needed to perform procedures correctly, emphasizing preventive maintenance.
Manual Type:
Service Repair Workshop Manual
Coverage Focus:
Maintenance, diagnostics, repair, and overhaul of specified Hyundai forklift models.
Page Count:
Not specified in product information, but typical for comprehensive workshop manuals.
Compatibility:
All Versions of Windows & Mac
Software Requirements:
Adobe PDF Reader
Powertrain:
Detailed coverage of the powertrain system, including structure, operation, troubleshooting, and disassembly/assembly.
Brake System:
Comprehensive coverage of the brake system, including structure, function, operational checks, troubleshooting, tests, and adjustments.
Steering System:
In-depth information on the steering system, covering structure, function, operational checks, troubleshooting, and disassembly/assembly.
Hydraulic System:
Extensive details on the hydraulic system, including structure, function, operational checks, troubleshooting, and disassembly/assembly.
Electric System:
Thorough coverage of the electrical system, including component location, electrical circuits, and electric component details.
Mast:
Detailed sections on the mast, covering structure, operational checks, troubleshooting, adjustment, and removal/installation.
General:
Includes general information such as safety hints, specifications, and periodic replacement guidelines.
Control System:
Implied coverage of the electronic control units (ECUs) and their management of drive, lift, and tilt functions.
Maintenance:
Covers routine and preventive maintenance procedures to ensure optimal performance and longevity.
Troubleshooting:
Detailed troubleshooting guides for identifying and resolving common issues across various systems.
Disassembly Assembly:
Step-by-step instructions for the disassembly and reassembly of major components and systems.
Removal Installation:
Procedures for the removal and installation of major components and entire units.
Tests Adjustments:
Guidance on performing necessary tests and adjustments for various vehicle systems.
Depth:
Comprehensive, suitable for both amateur and professional technicians.
Diagnostic Tools:
Manual likely references specific diagnostic tools or procedures for AC motor controllers and system diagnostics.
Digital Format:
PDF, ensuring high-quality readability and searchability.
Searchability:
PDF format typically allows for keyword searching within the document, enhancing efficiency for technicians.
Printability:
Printable pages for on-site reference and hard copy needs.
Binding Type:
Not applicable (digital format).
Paper Type:
Not applicable (digital format).
Operator Interface:
Basic operator controls and dashboard indicators for lift functions, battery status, and operational parameters.
Features:
Built-in safety features like operator presence sensing, speed reduction during turns, and overload protection (depending on configuration).
Diagnostics:
On-board diagnostics (OBD) ports or specific diagnostic connectors for troubleshooting electrical and system faults.
Daily Checks:
Visual inspection, fluid levels (hydraulic, brake), tire condition, battery charge, horn, lights, and mast operation.
Monthly Checks:
Lubrication of moving parts, brake system checks, battery terminal cleaning, and tightening of visible fasteners.
Annual Service:
Full hydraulic system check, electrical system diagnostics, brake system overhaul, and comprehensive lubrication.
Hydraulic Fluid:
ISO VG 32 or 46 hydraulic oil (specific viscosity may vary based on operating temperature; consult manual).
Brake Fluid:
DOT 3 or DOT 4 brake fluid (check specific model requirements).
Grease:
General purpose lithium-based grease for lubrication points.
Common Problems:
Potential issues can include wear on lift chains, hydraulic leaks, battery degradation, wear on steer axle components, and electrical connection corrosion.
Filters:
Hydraulic filter (e.g., Part No. 31900-23001 or similar), transmission filter (if applicable), air filter (for operator compartment/electronics cooling).
Wear Items:
Tires, brake pads/shoes, lift chains, fork tines, hydraulic hoses, and electrical brushes (if applicable).
Steering Knuckles:
Requires regular greasing as per manual recommendations.
Mast Channels:
Lubrication of mast channels and rollers for smooth operation.
Drive Axle:
May require periodic checks and lubrication depending on the axle design.
Manufacturer:
Hyundai Heavy Industries (HHI) Material Handling Division, known for robust industrial equipment.
Series Designation:
The 'BC-9' series represents a generation of Hyundai electric forklifts focusing on efficiency and operator comfort.
Production Period:
Specific production years not provided, but BC-9 models are generally from the 2000s to early 2010s.
Capacity 20Bc-9:
2,000 kg (approximately 4,400 lbs)
Capacity 25Bc-9:
2,500 kg (approximately 5,500 lbs)
Capacity 30Bc-9:
3,000 kg (approximately 6,600 lbs)
Capacity 32Bc-9:
3,200 kg (approximately 7,050 lbs)
Type:
Counterbalanced Electric Forklift Truck
Motor Type:
AC Drive Motors (typical for this series)
Battery System:
Operates on industrial battery systems (voltage and capacity vary by configuration).
Mast Type:
Various mast configurations available (e.g., Duplex, Triplex) influencing lift height and collapsed height.
Tire Type:
Solid or Pneumatic tires (depending on application and model variant).
Overall Width:
Varies by model and tire configuration, typically around 1100-1300 mm.
Overall Length:
Varies by model and load backrest, typically around 2000-2500 mm (excluding forks).
Turning Radius:
Designed for maneuverability in tight spaces, often a counter-rotating drive axle configuration.
Type:
Hydraulic disc brakes or drum brakes (common in electric forklifts of this era), often with regenerative braking integrated into the drive system.
Lift Height:
Varies significantly based on mast type and configuration (e.g., 3000mm to 6000mm+). Consult specific model data.
Free Lift:
Dependent on mast design, important for low-clearance operations.
Type:
Power steering, typically electric power steering (EPS) or hydrostatic power steering.
