GENERAL

INFORMATION
CHASSIS NUMBER NAMEPLATE ...... GI - 2
GENERAL SERVICE INFORMATION . GI - 3
PRECAUTIONS FOR ELECTRIC
WELDING ............................................... GI -12
GI -2 GENERAL INFORMATION

GENERAL K : Universe

5. Body Type
CHASSIS NUMBER NAMEPLATE ED1EEA98 TRUCK
• A- Cargo / Top Truck Type B- Full Cargo Type
VEHICLE IDENTIFICATION NUMBER D- Van Type E- Double Cab Type
LOCATION K- Special Type

The vechicle identification number (V.I.N) is stamped on BUS

the outside part of side frame as below picture. • A- City C-City Express
J- Tour Bus L- Express
KM J KL 18 TP 7 C 000000
6. Vehicle Division
Country Serial 1- All vehicle
& Manufacture Number
Vehicle type Plant 7. Brake System
7-Hydraulic Brake System
Vehicle line Model year
& Body type 8-Pneumatic Brake System
Vehicle division Engine type
9-Compound Brake System
& Brake system / Driver type
8. Engine Type
SPYGI7001L
B-D6AB G-C6AB T-D6CB
C-D6AC S-D6CA V-D6AV

9. Check Digit Other

P-Left Hand Driver (LHD)
R-Right Hand Driver (RHD)

10. Model year or Product Year

4:2004 5:2005 6:2006
7:2007 8:2008 9:2009 A:2010 B:2011

11. Plant
U-Ulsan plant(in korea)
C-Cheonju plant(in korea)
KMJKL18TP7C000000 A-Asan plant(in korea)

SPYGI7002D
12. Serial Number (Vehicle Production)
000001-999999
VEHICLE IDENTIFICATION NUMBER

K M J K L 1 8 T P 7 C 0 0 0 0 0 1

1 2 3 4 5 6 7 8 9 10 11 12

SPYGI7002L

1. Geographic zone
K-Built in korea by HMC (Hyundai Motor company)

2. Manufacturer
M-Manufactured by HMC

3. Vehicle Type
B-Trailer F- Truck C- Special vehicle J-Bus E- Tractor

4. Vehicle Line
N : Aero Town
GENERAL GI -3

GENERAL SERVICE INFORMATION DISASSEMBLY

PROTECTION OF THE VEHICLE If the disassembly procedure is complex, requiring many

parts to be disassembled, all parts should be disassem-
Always be sure to cover fenders, seats, and floor areas bled in a way that will not aggect their performance or ex-
before starting work. ternal appearance.
PREPARATION OF TOOLS AND MEASURING 1. Inspection of parts
EQUIPMENT Each part, when removed, should be carefulley on
spected for malfunction, deformation, damage, and
Be sure that all necessary tools and measuring equipment other problems.
are available starting work.

SPECIAL TOOLS

Use special tools when they are required.

EAKE005C

2. Arrangement of parts
All disassembled parts should be carefully arranged
for effective reassembly.
EAKE005A
Be sure to separate and correctly identify the parts to
be repllaced from those that will be used again.

EAKE005D
GI -4 GENERAL INFORMATION

3. Cleaning parts for reuse REPLACEMENT

All parts to be used again should be carefully and
thoroughly cleaned by an appropriate method. Standard values, such as torques and certain adjust-
ments, must be strictly observed in the reassembly of all
parts.
If removed, the following parts should always be replaced
with new ones.
1. Oil seals
2. Gaskets
3. O-rings
4. Lock washers
5. Cotter pins (split pins)
6. Plastic nuts

EAKE005E

PARTS

When replacing parts, use HYUNDAI genuine parts.

EAKE005G

Depending on their location.

7. Selalant should be applied to gaskets.
8. Oil should be applied to the moving components of
parts.

EAKE005F
GENERAL GI -5

9. Specified oil or grease should be applied to the pre-

scribed locations (oil seals, etc) before assembly.

EAKE005I

RUBER PARTS AND TUBES

EAKE005H
Always prevent gasoline or from touching rubber parts or
ADJUSTMENT tubing.

Use gauges and testers to adjust correclty the parts to

standard values correctly.

ELECTRICAL SYSTEM

1. Be sure to disconnect the battery cable from the neg-

ative (-) terminal of the battery.

2. Never pull on the wires when disconnecting connec-

tors.

3. Locking connectors will click when the connector is

secure.

4. Handle sensors and relays carefully. Be careful not to

drop them against other parts.

EAKE005J

MEASURING BODY DIMENSIONS

1. Basically, all measurements in this manual are taken

with a tracking gauge.

2. When a measuring tape is used, check to be sure

there is no elongation, twisting or bending.

3. For measuring dimensions, both projected dimen-

sioners and actual - measurement dimensions are
used in this manual.
GI -6 GENERAL INFORMATION

DIMENSIONS PROJECTED

1. These are the dimensions measured when the mea-

surement points are projected from the vehicle’s sur-
face, and are the reference dimensions used for used
for body alterations.

2. If the length of the tracking gauge probes is ad-

Ac
justable, measure it by lengthening one of two probes tu
al
as long as the different value in height of the two ly
-m
surface. ea
su
re
d
di
m
en
si
on

EAKE005L

Height
MEASUREMENT POINT

Measurements should be taken at the center of the hole.

Projected dimension

Hole center

EAKE005K

MEASURING ACTUAL DIMENSIONS

1. These dimensions indicate the actual linear distance

between mesaurement points, and are used as the
reference dimensions when a tracking gauge is used
for measurement.

2. First adjust both probes to the same length (A=A’)

before measurement.

NOTE
Check the probes and gauge itself to make sure there EAKE005M

is no free play.
GENERAL GI -7

CHECKING CABLES AND WIRES CHECK FUSES

1. Check the terminal for tightness. A blade type fuse test taps provided to allow checking the
fuse itself without removing if from the fuse box. The fuse
2. Check terminals and wires for corrosion from battery is good if the test lamp lights up when one lead is con-
electrolyte, etc. nected to the test taps (one at a time) and the other lead is
grounded. (Turn the ignition switch so that the fuse circuit
3. Check terminals and wires for open corcuits. becomes operative)
4. Check wire insulation and coating for damage, cracks
and degrading.

5. Check the conductive parts of terminals for contact

with other metallic parts (vehicle body and other Fuse box
parts).

6. Check grounded parts to verify that there is complete

continuity between thier attaching bolt(s) and the ve-
hicle’s body.

7. Check for incorrect wiring.

8. Check that the wiring is so clamped to the prevent Test leads

contact with sharp corners of the vehicle body, etc.
or hot parts (exhaust manifold, etc.)

9. Check that the wiring is clamped firmy to provide

enough clearance from the fan pulley, fan belt and
other rotating or moving parts.
EAKE005O
10. Check that the wiring has a little space so that it can
vibrate between fixed and moving parts such as the SERVICING THE ELECTRICAL SYSTEM
vehicle body and the engine.
1. Prior to servicing the electrical system, be sure to
turn off the ignition switch and disconnect the battery
ground cable.

EAKE005R

EAKE005P
GI -8 GENERAL INFORMATION

2. Attach the wiring harnesses with clamps so that there 4. When installing any parts, be careful not to pinch or
is no slack. However, for any harness which passes damage any of the wiring harness.
the engine or other vibrating parts of the vehicle, al-
low some slack within a range that does not allow the
engine vibrations to cause the harness to come into
contact with any of the surronding parts and then se-
cure the harness by using a clamp.

EAKE005T

5. Never throw relays, sensors or electrical parts, or ex-

pose them to strong shock.

EAKE005R

3. If any section of a wiring harness interferes with the

edge of a parts, or a corner, wrap the section of the
harness with tape or something similar in order to pro-
tect if from damage.

EAKE005U

EAKE005S
GENERAL GI -9

6. The electronlic parts used in the computer, relays, etc. 8. When disconnecting a connector, be sure to grip only
are readily damaged by heat. If there is a need for the connector, not the wires.
service operations that may cause the temperature
to exceed 80 C (176 F), remove the electronic parts
before hand.

80˚C
(176˚F)

EAKE006C

9. Disconnect connector which have catches by press-

EAKE006A ing in the direction of the arrows shown the illustration.

7. Loose connectors cause problems. Make sure that

the connectors are always securely fastened.

EAKE006D

EAKE006B
GI -10 GENERAL INFORMATION

10. Connect connectors which have catches by inserting 12. To avoid overloading the wiring, take the electrical cur-
the connectors until they make a clicking sound. rent load of the optional equipment into consideration,
and determine the appropartate wire size.

Permissible current
Nominal SAE gauge In engine
size No. compart- Other areas
ment
0.3mm² AWG 22 - 5A
0.5mm² AWG 20 7A 13A
0.85mm² AWG 18 9A 17A
1.25mm² AWG 16 12A 22A
2.0mm² AWG 14 16A 30A
3.0mm² AWG 12 21A 40A
5.0mm² AWG 10 31A 54A

EAKE006E

11. When using a circuit tester to check continuity or volt-

age on connector terminals, insert the test probe into
the harness side. If the connector is a sealed con-
nector, insert the test probe through the hole in the
rubber cap until contacts the terminal, being careful
not to damage the insulation of the wires.

Test probe

Connector

Test probe

EAKE006G
GENERAL GI -11

TIGHTENING TORQUE TABLE OF STANDARD

PARTS

Bolt nominal Torque Nm (kg.cm, lb.ft)

Pitch (mm)
diameter (mm) Head Mark 4 Head Mark 7

EAKE004E KASD100Y EAKE004F EAKE004G

M5 0.8 3 ~ 4 (30 ~ 40, 2.2 ~ 2.9) 5 ~ 6 (50 ~ 60, 3.6 ~ 4.3)

M6 1.0 5 ~ 6 (50 ~ 50, 3.6 ~ 4.3) 9 ~ 11 (90 ~ 110, 6.5 ~ 8.0)
M8 1.25 12 ~ 15 (120 ~ 150, 9 ~ 11) 20 ~ 25 (200 ~ 250, 14.5 ~ 18.0 )
M10 1.25 25 ~ 30 (250 ~ 300, 18 ~ 22) 30 ~ 50 (300 ~ 500, 22 ~ 36)
M12 1.25 35 ~ 45 (350 ~ 450, 25 ~ 33) 60 ~ 80 (600 ~ 800, 43 ~ 58)
M14 1.5 75 ~ 85 (750 ~ 850, 54 ~ 61) 120 ~ 140 (1,200 ~ 1,400, 85 ~ 100)
M16 1.5 110 ~ 130 (1,100 ~ 1,300, 80 ~ 94) 180 ~ 210 (1,800 ~ 2,100, 130 ~ 150)
M18 1.5 160 ~ 180 (1,600 ~ 1,800, 116 ~ 130) 260 ~ 300 (2,600 ~ 3,000, 190 ~ 215)
M20 1.5 220 ~ 250 (2,200 ~ 2,500, 160 ~ 180) 360 ~ 420 (3,600 ~ 4,200, 260 ~ 300)
M22 1.5 290 ~ 330 (2,900 ~ 3,300, 210 ~ 240) 480 ~ 550 (4,800 ~ 5,500, 350 ~ 400)
M24 1.5 360 ~ 420 (3,600 ~ 4,200, 260 ~ 300) 610 ~ 700 (6,100 ~ 7,000, 440 ~ 505)

NOTE
1. The torques shown in the table are standard val-
ues under the following conditions :
• Nuts and bolts are made of galvanized steel
bar.
• Galvanized plain steel washers are inserted.
• All nuts, bolts and plain washers are dry.

2. The torques shown in the table are not applicable

:
• When spring washers, toothed washers and
the like are inserted.
• If plastic parts are fastened.
• If self-tapping screws or self-locking nuts are
used.
• If threads and surfaces are coated with oil.

3. If you reduce the torques in the table to the per-

centage indicated below, under the following con-
ditions, it will be the standard value.
• If spring washers are used : 85%
• If threads and bearing sufaces are stained
with oil : 85%
GI -12 GENERAL INFORMATION

PRECAUTIONS EDDE258D

PRECAUTIONS FOR ELECTRIC WELDING

WARNING
When electric-welding the electronic parts which
are con nected directly to the battery, current in
the welding machine can flow through the ground-
ing circuit to these parts, thus damaging them.
Follow below procedures surely.

1. Turn off all of the electric switches in vehicle.

2. Remove the (-) Battery.

3. Disconnect all of grounding circuits earthed in vehicle,

insulate the current using rubber and etc.

NOTE
Refer the Electrical Troubleshooting Manual in rela-
tion position of ground terminal.

4. Disconnect all ECU and controller connector.

Engine control system : ECU or ECM
Brake control system : ABS, ASR
The other system : ETACS

NOTE
Refer the Electrical Troubleshooting Manual in rela-
tion position of ground terminal.

5. Do not earth grounding circuit in the welding machine

to the fuel tank.

6. The welding spark should be contacted to the fuel

tank.

7. When tightening ground terminal to the body, clean

the neighborhood of body and tighten it with specified
torque.

Tightening torque.
Item Outer Diameter of bolt(mm)
Nm kgf·m lb-ft
Battery relay groung terminal M8 9.8~11.8 1~1.2 7.3~8.7
Battery connection(-) terminal M6 3.9~5.9 0.4~0.6 2.9~4.4
Battery connection(+) terminal M6 3.9~5.9 0.4~0.6 2.9~4.4
Battery(-) cable ring terminal M10 18.6~23.5 1.9~2.4 13.8~17.4
Battery(+) cable ring terminal M10 18.6~23.5 1.9~2.4 13.8~17.4
Battery(-) terminal M8 9.8~11.8 1~1.2 7.3~8.7
Battery(+) terminal M8 9.8~11.8 1~1.2 7.3~8.7