Hyundai 110D-9 Manual Download Page 248

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9-10

MAST

Problem

Cause

Remedy

Forks fail to lower.

Deformed mast or carriage.

Disassemble, repair or replace.

Fork fails to elevate

Faulty hydraulic equipment.

Deformed mast assembly.

See troubleshooting hydraulic pump

and cylinders in section 6, hydraulic
system.

Disassemble mast and replace

damaged parts or replace complete
mast assembly.

Slow lifting speed and
insufficient handling capacity.

Faulty hydraulic equipment.

Deformed mast assembly.

See troubleshooting hydraulic pump

and cylinders in section 6, hydraulic
system.

Disassemble mast and replace

damaged parts or replace complete
mast assembly.

Mast fails to lift smoothly.

Deformed masts or carriage.

Faulty hydraulic equipment.

Damaged load and side rollers.

Unequal chain tension between

LH & RH sides.

LH & RH mast inclination angles

are unequal. (Mast assembly is
twisted when tilted)

Disassembly, repair or replace.

See Troubleshooting Hydraulic

Cylinders, pump and control valve in
section 6, hydraulic system.

Replace.

Adjust chains.

Adjust tilt cylinder rods.

Abnormal noise is produced
when mast is lifted and lowered.

Broken load roller bearings.

Broken side roller bearings.

Deformed masts.

Bent lift cylinder rod.

Deformed carriage.

Broken sheave bearing.

Replace.

Disassemble, repair or replace.

Replace.

Abnormal noise is produced
during tilting operation.

Insufficient lubrication of anchor

pin, or worn bushing and pin.

Bent tilt cylinder rod.

Lubricate or replace.

Replace.

7. MAST AND FORK

Summary of Contents for 110D-9

Page 1: ...ns 1 6 6 Operator protection 1 7 7 Fork safety 1 8 8 Pinch points 1 9 9 Travel 1 10 10 Grades ramps slopes and inclines 1 11 11 Tip over 1 12 12 Surface and capacity 1 14 13 Parking 1 15 14 Refueling 1 16 15 Step 1 17 16 Operator s safety rules 1 18 17 Side shift 1 19 2 OPERATING HAZARDS 2 OPERATING HAZARDS 1 Loose loads 2 1 2 Long and wide loads 2 2 3 Rear swing 2 2 4 Low overhead clearance 2 3 5...

Page 2: ... inspection 4 1 2 Suggestion for new truck 4 3 3 Fuel safety practices 4 4 5 STARTING AND OPERATING PROCEDURES 5 STARTING AND OPERATING PROCEDURES 1 Before operating the truck 5 1 2 Check before operation 5 2 3 Check before starting engine 5 3 4 Seat adjustment 5 8 5 Starting from a safe condition 5 9 6 General starting and operating tips 5 10 7 Starting and stopping the engine 5 11 8 Warming up o...

Page 3: ...system 7 47 9 Air conditioner and heater 7 48 10 Replacement and check 7 49 11 Handling truck in extremely hot places 7 59 12 Cold weather operation 7 60 13 Recommendation table for lubricants 7 61 14 Fuel and lubricants 7 62 8 SPECIFICATIONS 8 SPECIFICATIONS 1 Specification table 8 1 2 Specification for major components 8 2 3 Tightening torque 8 6 9 TROUBLESHOOTING 9 TROUBLESHOOTING 1 Engine syst...

Page 4: ... it cannot cover every possible situation that may result in an accident You must watch for hazards in your work areas and avoid or correct them It is important that you know and understand the information in this manual and that you know and follow your company safety rules Be sure that your equipment is maintained in a safe condition Do not operate a damaged or malfunctioning truck Practice safe...

Page 5: ...for your safety A faulty lift truck is a potential source of danger to the operator and to other personnel working near it As with all quality equipment keep your lift truck in good operating condition by following the recommended schedule of maintenance Operator Daily Inspection Safety and Operating Checks A lift truck should always be examined by the operator before driving to be sure it is safe...

Page 6: ...effect at the time of printing HYUNDAI reserves the right to make improvements and changes in specifications or design without notice and without incurring obligation Please check with your authorized HYUNDAI dealer for information on possible updates or revisions The examples illustrations and explanations in this manual should help you improve your skill and knowledge as a professional lift truc...

Page 7: ...ing nearby Know your truck s capabilities and limitations Follow all instructions in this manual including all symbols and messages to avoid damage to your lift truck or the possibility of any harm to yourself or others This manual is intended to be a permanently attached part of your lift truck Keep it on the truck as a ready reference for anyone who may drive or service it If the truck you opera...

Page 8: ...2000 14 EC and EN 12053 are as followings EC REGULATION APPROVED Model 110D 130D 160D 9 LPA 75 dB LWA EU only 105 dB ÂThe value of vibrations transmitted by the operator s seat are lower than standard value of 2005 88 EC ...

Page 9: ...ution 26 Safety work 29 Accumulator 30 Start procedure 31 Load capacity 32 Air compressor cab 33 Safety instruction OPSS 34 Hammer 35 Fire extinguisher 36 Grease 38 Name plate 43 Tilt warning 1 LOCATION Always keep these labels clean If they are lost or damaged attach them again or replace them with a new label VIEW A 1 1 A C B 1 3 3 4 4 5 6 RADIATOR TOP VIEW 7 8 9 CONSOLE BOX 10 11 12 34 33 32 13...

Page 10: ...under the forks it is essential to support the carriage with blocks 1 25L7A0OM06 TEMPERATURE Item 8 This warning label is positioned on the top side of engine hood rear cover Coolant must be checked as specified in the maintenance chart 2 25L7A0OM10 RADIATOR ltem 7 This warning label is positioned on the top side of engine hood rear cover It forbids to open the filler cap of the surge tank because...

Page 11: ...the maintenance chart Refer to page 5 3 for the regulated tire air pressure A and B 92AT 00830 kgf cm A PSI B 6 25L7A0OM08 HOOK Item 5 This warning label is positioned near the lifting bracket on the engine hood rear cover and the top side of mast LH and RH Refer to page 5 34 for safe loading procedures 7 ö 92AM 00630 RADIATOR FAN Item 6 This warning label is positioned on the top side of cooling ...

Page 12: ...the fuel supply line Repeat the previous steps until fuel is exiting at the supply line Tighten the banjo bolt at the supply line Re cranking If the engine still would not start please contact the nearest HYUNDAI or Cummins dealers 8 91LC 11170 START WARNING Item 13 This warning label is positioned on the middle top side of dashboard Start key switch after 5 6 seconds from ON position It needs app...

Page 13: ...tor existence sensing system per ANSI ASME B56 1 7 21 10 and 7 21 11 Please review Operator s manual for safe operation of forklift Power travel movement of the truck shall be possible only if the operator is in the normal operating position Transmission will automatically shift to neutral upon the exiting of the operator The Forward Reverse lever must be cycled through neutral with the operator i...

Page 14: ... event of a tip over Outstretch the legs as widely as possible and grasp firmly the steering handle Lean the body to the opposite direction in order to avoid severe injury or death when the truck is tipped over Refer to page 3 3 1 2 3 4 5 6 7 25L7A0OM09 1 13 1 2 3 4 5 6 7 ö CABIN TILT UP DOWN Item 16 This warning label is positioned on the left side of frame 92FT 40720 14 92FT 40720 When tilting c...

Page 15: ... 8 for details 17 ö ö 97HN 00910 NOISE LEVEL Item 22 This warning label is located on the right side of the engine hood 18 91FU 00200 FIRE EXTINGUISHER Item 35 This label is located on the rear left of the cabin inside Read and understand the instructions adhered decal on the fire extinguisher 19 ö 91B1 01600 91B1 01600 TILT WARNING Item 43 This warning label is positioned on the left side of fram...

Page 16: ...n the accumulator of the solenoid valve The accumulator is filled with high pressure nitrogen gas and it is extremely dangerous if it is handled in the wrong way Always observe the following precautions Never make any hole in the accumulator expose it to flame or fire Do not weld anything to the accumulator When carrying out disassembly or maintenance of the accumulator or when disposing of the ac...

Page 17: ...or the harness Do not touch the cabin tilting cylinder head during the operation Refer to page 3 36 for air compressor switch 24 1 2 3 4 5 6 7 ö AIR COMPRESSOR TANK Item 23 This label is positioned on the top side of the air tank Do not touch the cylinder head during the operation or it may cause severe burn 25 91Q4 13300 91Q4 13300 91FT 13320 2 Be sure the engine working during the use of air com...

Page 18: ...ted on the left stay of the cabin inside The rear window serves as an alternate exit To remove rear window pull the ring and push out the glass 27 ö ö 91Q6 07280 91Q6 07280 SCR Item 18 This label is located on the left side of the frame Do not touch the aftertreatment device or it may cause severe burn When the engine is running or immediately after engine shut down SCR Selective Catalytic Reducti...

Page 19: ...wing when you order parts or the truck is out of order TRUCK SERIAL NUMBER It s shown on front of the right side frame 1 160D7SM02 ENGINE SERIAL NUMBER The numbers are located on the engine name plate 2 Important safety hint It indicates matters which can cause the great loss on the truck or the surroundings It indicates the useful information for operator 3 SYMBOLS ö Engine serial No 290F0SL02 ...

Page 20: ...aintenance and lubrication table Check for damage and maintenance problems Have repairs made before you operate the truck Do not make repairs yourself Lift truck mechanics are trained professionals They know how to make repairs safely 110D9OM02 1 SAFETY HINTS 1 DAILY INSPECTION ...

Page 21: ...5AOM03 Do wear safety equipment when required D35AOM05 Don t mix drugs or alcohol with your job Don t block safety or emergency equipment 110D9OM04 D35AOM02 Don t smoke in NO SMOKING areas or when refueling D35AOM06 2 DO S AND DON TS ...

Page 22: ...he truck outdoors in rainy day öExclude the truck equipped cabin 110D9OM07 Exhaust gas is dangerous Do not operate the truck at the inhouse if possible Provide adequate ventilation when working in a closed space 110D9OM08 ...

Page 23: ...1 4 3 SEAT BELTS Seat belts can reduce injuries 160D7OM11 Always buckle up for the truck equipped with safety belt 160D7OM09 ...

Page 24: ...1 5 110D9OM12 110D9OM14 4 NO RIDERS The operator is the only one who should be on a truck Never transport personnel on the forks of a lift truck 1 2 ...

Page 25: ...same roadway you do Sound your horn at all intersections or blind spots 110D9OM05 Watch for people in your work area even if your truck has warning lights or alarms People may not watch for you D35AOM14 Watch for people standing back even when you are parked 110D9OM06 5 PEDESTRIANS 1 2 3 ...

Page 26: ... 7 6 OPERATOR PROTECTION 110D9OM16 Stay inside the cabin Always keep your body within the confines of the truck Do not operate truck without cabin or overhead guard unless condition prevent use of it 1 2 ...

Page 27: ...ised forks D255OM17A There is special equipment to raise people for overhead work DO NOT USE LIFT TRUCKS 110D9OM14 Always lower the load slowly Raise and lower with mast vertical or tilted slightly back Never forward 110D9OM17 7 FORK SAFETY ...

Page 28: ...hands feet and legs out of the mast D255OM61 Don t use the mast as a ladder 110D9OM62 Never try to repair the mast carriage chain or attachment by yourself Always get a trained mechanic 110D9OM63 8 PINCH POINTS ...

Page 29: ...g bulky loads that restrict your vision operate your truck in reverse to improve visibility Be sure to pivot in the seat to give maximum visibility 110D9OM25 Unstable loads are a hazard to you and to your fellow workers Always make certain that the load is well stacked and evenly positioned across both forks Never attempt to lift a load with only one fork Wrong 110D9OM26 9 TRAVEL 1 2 3 ...

Page 30: ...1 11 10 GRADES RAMPS SLOPES AND INCLINES 110D9OM30 110D9OM33 Unloaded Forks downgrade Loaded Forks upgrade 1 2 Never turn on a grade either loaded or unloaded ...

Page 31: ...even more likely with excessive forward tilt braking in forward travel or accelerating rearward Longitudinal tip over can occur by driving with the load down slope on a steep grade Lateral and longitudinal tip over can occur if the truck is driven over objects on the floor or ground off the edge of improved surfaces or into potholes in the road surface or by running into overhead objects or collis...

Page 32: ...not jump Brace yourself as illustrated right 1 Make sure your seat belt is fastened securely if the truck is equipped with seat belt 2 Stay in your seat 3 Grip the wheel 4 Brace your feet Your chances for survival in a tip over are better if you stay with the truck in your seat 3 1 2 4 ...

Page 33: ...UCKLE UP 110D9OM40 160D7OM11 Avoid these conditions They can cause a truck to tip over or lose traction for braking or driving Know the weight of your truck and load Especially when using elevators know the capacity of the elevator you intend to use Do not overload 12 SURFACE AND CAPACITY ...

Page 34: ...g the truck Be sure the travel control is in NEUTRAL 160D7AOM42 Lower forks fully to the floor and tilt forward ON OFF START 1 2 160D7AOM44 Put the parking brake switch in LOCK position Position 1 Release Position 2 Lock Turn start switch to OFF position 13 PARKING 1 2 3 4 5 50D9OM37 ...

Page 35: ...dding fuel check around truck for oil leakage 110D9OM47 Keep away from fire when adding fuel or during operation DIESEL 110D9OM48 After adding fuel wipe off any fuel spilled on the truck 110D9OM49 14 REFUELING 1 2 3 ...

Page 36: ...1 17 When getting on or off the truck use the step provided 110D9OM50 Do not jump up or down from the truck 110D9OM52 15 STEP 1 2 ...

Page 37: ...rating position to regain powered directional control Parking brake warning This function works when the key switch is not only ON or START position but also OFF position Alarm sounds in 2 seconds from the driver s off the seat with the parking brake released To release the function the parking brake switch must be turned to LOCK position When the key switch is OFF position alarm will sound only f...

Page 38: ...the stability of truck and may cause over turning Avoid overloading or uneven loading Load on the forks according to load capacity mentioned on the truck name plate when sideshift is applied Uneven loading will deteriorate the stability of the truck when the load is raised Top of the load should not extend above the backrest 110D91SS01 110D91SS04 110D91SS02 110D91SS03 ...

Page 39: ... precautions Never carry loose or uneven material 110D9OM53 Center wide loads 110D9OM55 Stack and band loose material D35AOM41 Avoid sudden braking or starting When the truck is loaded do not drive at maximum speed 110D9OM56 2 OPERATING HAZARDS 1 LOOSE LOADS ...

Page 40: ... load elevated do so with extreme care and be alert to load end swing when turning A long load reduces the capacity of the truck Know and understand your truck load rating 110D9OM57 When turning be sure the rear end of the truck does not swing into racks posts etc Watch for pedestrians beside the truck 110D9OM43 2 LONG AND WIDE LOADS 3 REAR SWING ...

Page 41: ...nce Moving into overhead structures can tip a truck over or spill a load 110D9OM74 Slow down before turning The truck can tip over 110D9OM46 Turn too sharp with a raised load and your truck can tip even at slow speeds Travel with a load raised only when removing or depositing a load 110D9OM56 4 LOW OVERHEAD CLEARANCE 5 FAST TURNS AND HIGH LOADS ...

Page 42: ... and move slowly 6 RIGHT ANGLE STACKING 110D9OM75 Slack chains mean rail or carriage hang up Raise the forks before you move or broken chains can result In case forks with loads are stuck while lowering the mast lift the mast again and prevent chains from being slack 7 CHAIN SLACK D35AOM51 D35AOM52 ...

Page 43: ... the truck The operating near the electrical lines is very dangerous Operate within safe working permitted as below 9 CAUTION FOR ELECTRICAL LINES 110D9OM76 110D9OM77 If the truck touches the electric power lines keep sitting on the operator s seat and make sure the personnel on the ground not to touch the truck until turning off the electric current Jump off the truck without contacting the truck...

Page 44: ...2 6 Never permit any persons to stand or pass under lifted load 10 LIFTING LOADS 110D9OM58 110D9OM60 Never use wire rope to lift a load ...

Page 45: ... operator lift or lower the load without shifting it in the netural position it can be overturned the forklift due to unstabled load When lifting or lowering the side shift with load it should be observed that the load is moved into the netural position 110D9OM74A Never operate the side shift while the forks are not equipped with supports such as a load table for the load Never travel the forklift...

Page 46: ...he fork positioner suddenly and quickly It can be caused to drop the load 110D9OM75A 12 FORK POSITIONER 13 SOLID TIRE Do not travel more than 25 km hr 16 mph Do not travel further than 8 km 5 miles in an hour Do not drive on the road for automobile Our warranty does not cover any damages caused by excessive driving 1 2 3 ...

Page 47: ...nt wheel 9 Head lamp fender 10 Tilt cylinder 11 Work lamp mast 12 Rear view mirror 13 Rear wheel 14 Bonnet 15 Counterweight 16 Rear combination lamp 17 Silencer 18 Air conditioner opt 19 Rear work lamp 20 Cabin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 20 18 110D9OM54 1 3 KNOWYOUR TRUCK 1 GENERAL LOCATIONS ...

Page 48: ...h the attachment Capacity rating load center and lifting height data Shows the maximum load capacity of this truck with relation to load centers and fork heights See diagram on plate Personal injury and damage to the truck can occur if these capacities are exceeded Do not exceed the maximum capacity specified Truck weight The approximate weight of the truck without a load on the forks This weight ...

Page 49: ... decals Operator Tip over warning decal This decal is located on cabin s upper left side frame Its purpose is to remind the operator that staying in the seat provides the best chance of avoiding injury in the event of a truck tipping or driving off a dock mishap Lift trucks can be tipped over if operated improperly Experience with lift truck accidents has shown that the driver cannot react quickly...

Page 50: ...ke pedal Handsfree Remote controller The ergonomically designed console box and suspension type seat provide the operator with comfort ELECTRONIC MONITOR SYSTEM The centralized electronic monitor system allows the status and conditions of the truck to be monitored at a glance It is equipped with a safety warning system for early detection of truck malfunction 1 2 1 2 110D9CD01 Remote control lever...

Page 51: ...witch board Aircon heater switch opt Cluster Steering wheel Gear selector lever Inching pedal Multi function switch Accelerator pedal Operator seat Brake pedal Handsfree opt Remote controller opt 160D9LCD01 1 Fingertip type Machine serial number 110D 9 0075 130D 9 0030 160D 9 0156 ...

Page 52: ...us of the truck Warning lamps Indicate abnormality of the truck Pilot lamps Indicate operating status of the truck LCD Display the truck model error code and engine speed etc Buttons Select the truck model error code and engine speed etc and stop the buzzer sound The cluster installed on this truck does not entirely guarantee the condition of the truck Daily inspection should be performed accordin...

Page 53: ...engine at low speed until the indicator is in the operating range If the indicator is in the red range turn OFF the engine and check the radiator and engine If the gauge indicates red range even though the truck is on the normal condition check the electric device as that can be caused by the poor connection of electricity or sensor This range indicates the temperature of transmission oil White ra...

Page 54: ... lamp 2 SCR cleaning warning lamp Engine stop warning lamp Engine oil pressure warning lamp Water in fuel warning lamp Brake oil pressure warning lamp Brake oil temp warning lamp Transmission error warning lamp Air cleaner warning lamp Fuel low level warning lamp Engine coolant temp warning lamp Transmission oil temp warning lamp DEF low level warning lamp Engine check warning lamp Battery charge ...

Page 55: ...harging circuit when this lamp comes ON during engine operation Fill the fuel immediately when the lamp is turned ON This lamp operates by the vacuum caused inside when the filter of air cleaner is clogged Check the filter and clean or replace it when the lamp is ON Air cleaner warning lamp Battery charging warning lamp Fuel low level warning lamp 4 5 6 Light up when water in fuel Stop the engine ...

Page 56: ...during operation stop the engine and check the truck This lamp lights ON and the information window of the LCD shows the error code when an error occur in the transmission Immediately pull the truck to a convenient stop Stop the engine Investigate the cause Consult a HYUNDAI dealer to investigate the cause Do not operate until the cause has been corrected Transmission oil temperature warning lamp ...

Page 57: ...arning Flash On DEF level 0 Engine error code 3547 3714 50 derate 30 min DEF level final derate warning Flash On On Engine error code 3712 Contact Hyundai service center or dealer Manual SCR cleaning applies if the truck is in a fireproof area and there is no plan to turn off the truck during the SCR cleaning Stop and park the truck Push the switch to position to initiate the manual SCR cleaning R...

Page 58: ...or detail DEF Diesel Exhaust Fluid low warning lamp 14 When this warning lamp lights ON stop the engine immediately and and check the DEF level and related parts of the engine Please contact your Hyundai service center or local dealer This lamp is turned ON when the cooling fan error occurs Engine stop warning lamp Fan error warning lamp 50D9CD32 50D9CD33 180D9CD14 15 16 ...

Page 59: ...CR cleaning inhibit pilot lamp HEST pilot lamp Preheater pilot lamp Fuel warmer pilot lamp Inching pilot lamp Expendables replacement pilot lamp Right turning pilot lamp Parking brake pilot lamp Head light pilot lamp Left turning pilot lamp DEF level pilot lamp Cooling fan reverse pilot lamp 300D9CD02 2 When the warning and pilot lamps are illuminated more than display you can display next lamps b...

Page 60: ... warmer pilot lamp 6 50D9CD14 OPSS pilot lamp 7 This signal lamp lights ON when the operator leaves the seat Powered travel movement of the truck shall be possible only if the operator is in the normal operating position Transmission will automatically shift to neutral upon the exiting of the operator The gear selector lever must be cycled through neutral with the operator in the normal operating ...

Page 61: ...t will be common for the lamp to illuminate on and off during normal equipment operation as the engine completes the SCR cleaning HEST High exhaust system temperature pilot lamp 9 50D9CL003 This pilot lamp lights ON when the SCR cleaning switch is pushed inhibit position therefore automatic and manual SCR cleaning can not occur It should inhibited before caused fire due to the exhaust gas in high ...

Page 62: ... Move in menu left up right down Decrease Increase input value When the warning and pilot lamps occur over six you can display next lamps by push the button Buzzer stop ESC button 1 Menu button Move button 2 3 CLUSTER BUTTON 4 50D9CD121 Menu button Camera Enter button Move button Buzzer stop ESC button 50D9CD24 50D9CD23 50D9CD22 50D9CD25 Enter button Change the camera screen on main This button is...

Page 63: ...ht button in the cluster button for about 4 seconds it directly connected to the current failure screen Warning lamp Engine Transmission and Air conditioner 1 2 LCD 5 180D9CD10 180D9CD13 50D9CD11 300D9CD12 Main menu screen Main screen Communication error Sub menu screen MENU Main screen when occurred communication error between the cluster and TCU MCU ECU 1 Engine rpm 2 Load indicator opt 3 Hour m...

Page 64: ... history Maintenance management Signal statue User password change Opening of communication Current history logged history and delete logged fault Replacement Change interval oils and filters Display information of sensors User password change 5 10 digit Orbcomm GPS antenna 3 LCD adjustment Time setting Unit setting Language setting AS phone number ESL password change Maintenance management LCD br...

Page 65: ...odel Turn the lift truck ON after turn it OFF when changing D 9 to D 9H or D 9H to D 9 The initial model is selected at the factory so don t change the different model Equipment Choose the equipment Model select 3 180D9CD20 180D9CD22 50D9CD21 300D9CD12 300D9CD302 50D9CD23 300D9CD303 300D9CD300 300D9CD304 300D9CD301 300D9CD305 50D9CD25 ...

Page 66: ...rklift truck steering angle Display set to approve a condition Right set rear wheel calibration Center set rear wheel calibration Left set rear wheel calibration Setting for rear wheel angle Tilt setting 180D9CD29 180D9CD26 180D9CD30 1 50D9CD27 180D9CD31 180D9CD28 180D9CD32 180D9CD34 1 180D9CD33 ...

Page 67: ...he weight In the loaded from the ground waiting 5 seconds after lift 30 cm Weight correction ON Weight sensor setting Cross section Load weight adjust a b 180D9CD35 1 180D9CD36 1 50D9CD39 1 50D9CD39 1 180D9CD37 50D9CD40 50D9CD44 180D9CD38 180D9CD41 50D9CD45 1 50D9CD42 180D9CD46 50D9CD47 1 50D9CD47 Mast spec 110 130D 9 160D 9 V Mast 190 07 226 19 VS Mast 226 19 265 46 TS Mast 226 19 265 46 ...

Page 68: ...us 50D9CD39 1 50D9CD49 50D9CD50 1 50D9CD51 1 180D9CD35 1 Select the number of points of weight value display Choose using buzzer when over weight Weight display setting Overload warning buzzer c d 180D9CD35 1 180D9CD35 1 50D9CD53 1 50D9CD57 1 50D9CD54 50D9CD58 1 50D9CD55 ...

Page 69: ...or starting Set time 5 minutes for starting In 5 minutes you can restart without password but after 5 minutes you should input password for starting ESL setting 180D9CD59 50D9CD60 180D9CD61K 50D9CD63 50D9CD61 3 50D9CD62 50D9CD61 2 50D9CD64 1 180D9CD55 180D9CD55 180D9CD55 ...

Page 70: ...n When it is finished OK sign at gear box Press Menu ECS Enter button Start the engine AEB start KEY ON Brake pedal sensor calibration Software version check for MCU Cluster RMCU Vehicle max speed limit AEB setting R MCU Cluster information 180D9CD65 1 180D9CD71 1 180D9CD73 1 50D9CD66 1 180D9CD72 50D9CD74 1 50D9CD67 50D9CD68 180D9CD69 50D9CD70 1 ...

Page 71: ... you hold down the manual button Automatic The fan rotate in reverse direction at pre set interval Interval 30 minutes 5 hours Time 30 seconds 5 minutes Refer to the page 3 35 for the cooling fan control switch Cooling fan reverse mode 180D9CD101 1 180D9CD103 1 ...

Page 72: ...0D9CD403 50D9CD405 50D9CD407 50D9CD404 50D9CD406 50D9CD408 50D9CD409 50D9CD410 Ability to set up the maximum Pull Push Min Max value and neutral value Mid of lever Finger Tip lever set up about 0 5V 2 5V 4 5V You must be to move with actual Lever Unit V ex Min 0 48 Mid 2 52 Max 4 52 ...

Page 73: ...utral Lever state 2 5V ex If you set up the Upper 0 26 Lower 0 24 Lever operating range will be Upper zone 2 76V 2 5 0 26 4 5V Lever Max value Lower zone 2 26V 2 5 0 24 0 5V Lever Min value 50D9CD400 50D9CD401 50D9CD411 50D9CD412 50D9CD414 50D9CD416 50D9CD413 50D9CD415 50D9CD417 50D9CD418 50D9CD419 ...

Page 74: ...movements according ot the current value Unit Over 110D 9 only mA Under 80D 9 Only ex If the Max value increase the maximum speed will also increase If the Min value increase the minimum speed will also increase 50D9CD400 50D9CD420 50D9CD421 50D9CD422 50D9CD424 50D9CD426 50D9CD423 50D9CD425 50D9CD427 50D9CD428 50D9CD429 ...

Page 75: ...atus of the current engine transmission and or air conditioner Air conditioner Option DCU D 9H Only Show the logged fault status from the past of the engine transmission and or air conditioner Air conditioner Option DCU D 9H Only 180D9CD77 180D9CD77 180D9CD77 1 180D9CD77 2 300D9CD78 300D9CD306 180D9CD79 180D9CD79 180D9CD80 1 180D9CD80 1 Failure history a Current failure history b Logged fault hist...

Page 76: ... Delete the old item when Information have more than 10 Maintenance management 180D9CD81 180D9CD84 180D9CD82 180D9CD85 180D9CD88 1 180D9CD83 180D9CD87 180D9CD86 Initialize of the past logged fault history Air conditioner Option DCU D 9H Only 180D9CD77 180D9CD77 3 300D9CD307 180D9CD79 1 c Delete logged fault ...

Page 77: ... information of each sensors Signal status 180D9CD89 1 50D9CD90 50D9CD92 180D9CD97 180D9CD91 180D9CD93 You should set password by five to ten digit User password change 180D9CD94 1 50D9CD95 1 50D9CD96 1 50D9CD97 1 ...

Page 78: ...When successfully opened RMCU communication except for the RMCU comm Opening of communication 180D9CD98 1 180D9CD102 1 180D9CD102 180D9CD107 180D9CD99 180D9CD104 1 180D9CD101 180D9CD106 180D9CD100 180D9CD105 1 ...

Page 79: ...0D9CD110 180D9CD117 180D9CD111 180D9CD113 50D9CD112 180D9CD114 180D9CD115 Manual Manual setting for LCD brightness Automatic Automatic control of LCD brightness as set level of Day Night Setting day time Set the time for daylight If you set the time for daylight the rest time will be night Set the time Year Month Day Hour Minute AM PM ...

Page 80: ...ice 13 Multiple language You should set password by five to ten digit Check and change of contact information for customer service Language setting ESL password change A S phone number 180D9CD120 50D9CD127 50D9CD124 180D9CD121 180D9CD128 180D9CD130 50D9CD125 180D9CD122 50D9CD119 180D9CD129 180D9CD126 50D9CD123 180D9CD130 1 ...

Page 81: ...3 26 Show the maintenance information replacement cycle elapsed time change count alarm information Maintenance management 50D9CD131 50D9CD132 1 50D9CD133 1 ...

Page 82: ...nformation about the selected driving range The automatic range is symbolized by arrows above and below the bar indicator In case of possible errors in the system a wrench appears on the display combined with indication of the error number Also sporadically occurring errors can be indicated 1 If it happens error codes consult with Hyundai service center to repair the fault 180D93ACD33 Transmission...

Page 83: ...low raise enging speed E Engine speed too high lower enging speed T Transmission oil temperature too low heat up transmission T Transmission oil temperature too high cool down transmission FT Transmission temperature not in defined range during calibration Transmission stays in neutral you have to restart the TCU ignition off on FB Operating mode not NORMAL or transmission temperature sensor defec...

Page 84: ...ched and hold this position IP Release the pedal slowly until endposition is reached IP blinkt A problem occurred release the pedal slowly until endposition is reached If the expected endposition could not be reached release the pedal and try again OK Finished inchpedal calibration successful FN and Stop Shift lever not in Neutral position Calibrations is aborted FS and Stop Sensor supply voltage ...

Page 85: ...n decrement switch SCR cleaning switch Seat heater switch opt Hazard switch opt Parking brake switch Auto manual changeover switch Power standard switch Rear wiper washer switch Top wiper washer switch opt Air compressor switch opt Center horn Multi function switch Start switch Cover 250D9CD06 Remote control lever type Machine serial number 110D 9 0074 130D 9 0029 160D 9 0155 ...

Page 86: ...opt In decrement switch SCR cleaning switch Seat heater switch opt Hazard switch opt Parking brake switch Power standard switch Rear wiper washer switch Top wiper washer switch opt Air compressor switch opt Cover Master switch Center horn button Multi function switch Start switch 110D9CD106 Fingertip type Machine serial number 110D 9 0075 130D 9 0030 160D 9 0156 ...

Page 87: ...rake engaged the brake will overheat and may cause the brake system to go out of order 4 1 2 MAIN LIGHT SWITCH This switch is used to operate the head light by one steps First step Clearance lamp and cluster illumination lamp comes ON Also all of the pilot lamps of switches come ON Second step Head lamp comes ON Refer to page 3 34 for head lamp 5 1 50D9CD45 START SWITCH There are three positions O...

Page 88: ...the bottom of the switch fully for the autoshift function changing from 2nd to 3rd gear shift mode 1 2 3 7 1 2 3 50D9CD49 8 Horn By pressing position the horn sounds and by releasing the horn stops Sound the horn to warn near by personnel before tilting the cabin Tilting of the cabin Press the cabin tilt switch in order to tilt the cabin to right side or return to original location Refer to page 7...

Page 89: ...ON 35D9AOM18 This switch turn ON the strobe light 1 11 10 When engine running the low idle rpm of engine increase or decrease by 25 rpm by operating this switch Engine low idle rpm returns to normal value when engine restarted This switch is used to operate the wiper and washer on the top of the cab The washer liquid is sprayed and the wiper is operated only while pressing this switch OFF ON INC D...

Page 90: ...ck to other vehicles or equipment Push the lever up for turning left pull the lever down for turning right Dimmer switch This switch is used to turn the head light direction Switch positions Up To flash for passing Middle Head light low beam ON Down Head light high beam ON If you release the switch when it s in up position the switch will return to middle 3 2 Up Down M Left turning Right turning 7...

Page 91: ...is illuminated HEST lamp will be illuminated during the entire SCR cleaning Refer to the page 3 10 for details This switch return to the OFF position when released the manual position 1 2 3 4 SCR Selective Catalytic Reduction CLEANING SWITCH 1 2 OFF 50D9OM21A 18 REAR WIPER WASHER SWITCH This switch is used to operate the wiper and washer on the rear of the cab The washer liquid is sprayed and the ...

Page 92: ...erse according to set up interval and time of the cooling fan reverse mode Refer to page 3 21 1 to set of the cluster OFF Only forward rotation is possible MANUAL The fan rotates reverse only while pressing this position If release the switch return to the OFF position The reverse rotation pilot lamp lights up on the area of the warning and pilot lamp of the LCD when the cooling fan is operated to...

Page 93: ...lt lever Remote control lever type Fingertip type Steering wheel Gear selector lever Inching pedal Accelerator pedal Brake pedal Lift lever Tilt lever 3 spool lever opt 4 spool lever opt 5 spool lever opt Steering wheel adjusting lever 7 CONTROL DEVICE 160D9LCD08 ...

Page 94: ...ever is released the lifting or lowering action stops Lifting speed is controlled by lift lever and accelerator pedal Lowering speed is controlled by lever only Lower Lift LIFT LEVER 1 1 2 3 50D9CD12 Tilt forward Tilt backward TILT LEVER 2 50D9CD16 Tilt forward Push the lever forward to tilt mast forward Tilt backward Pull the lever back to tilt mast backward Holding When the lever is released til...

Page 95: ...usly outward of the both forks Pucker up the forks Pull the lever backward to pucker up simultaneously inward of the both forks Outstrech Pucker up LEVER FOR SIDE SHIFT WITH FORK POSITIONER Fork positioner synchronizer type 4 50D9CD19 1 1 LH fork movement Push the lever forward to move outward for the LH fork Pull the lever backward to move inward for the LH fork Outward Inward Fork positioner ind...

Page 96: ...ing on the brake pedal unnecessarily or bring premature wear of brake disc 1 BRAKE PEDAL 7 160D7ECD31 A steering cylinder of the steering axle will operate the steering function Turning the steering wheel left the truck moves to the left side and turning it right the truck moves to the right side STEERING WHEEL 6 1 2 110D9CD33 This lever is used for gear selection forward 3 stages and reverse 3 st...

Page 97: ... in the desired position After adjusting try to move the steering wheel backward and forward to check that it is locked in the selected position Always carry out the adjustment with the truck stopped Never try to adjust the steering wheel when the truck is moving Pull the handle attached on the bolt side of engine hood to open it STEERING WHEEL ADJUSTING LEVER ENGINE HOOD 1 2 3 1 110D9CD70 50D7ACD...

Page 98: ...for pleasant operation against outside temperature and defrost on window glass 8 AIR CONDITIONER AND HEATER 110D9CD90 AIR CONDITIONER BUTTON When you push this button air conditioner system is operated Determines whether to perform a cooling function of air conditioner Pilot lamp ON Air conditioner operation Pilot lamp OFF Fan only The AUTO pilot lamp ON when this button is pushed 1 2 50D9CD50 1 ...

Page 99: ...in the cab The pilot lamp is turned ON when the button is pushed Check out the fresh air filter periodically to keep a good efficiency Change air occasionally when using recirculation for a long time Check out the recirculation filter periodically to keep a good efficiency AIR INLET CONTROL BUTTON 50D9CD52 Fan speed is controlled automatically by set temperature The AUTO pilot lamp ON when the air...

Page 100: ...heck In cabin temperature sensor short Evap sensor open 1 Check assembly status 2 Evap sensor exchange after single item check Evap sensor short Water Valve sensor open 1 Check assembly status 2 Mix actuator exchange after single G P S Circuit Error 1 Check assembly status 2 Please refer to the type of fault diagnosis using gauge 3 Failure diagnosis and measures Failure diagnosis of gauge type 6 D...

Page 101: ...Monitor option Cigar lighter Handsfree option Remote controller option 12V socket Seat TCU MCU ECU Fuse box Handsfree option Remote controller option 12V socket Machine serial number 110D 9 0075 130D 9 0030 160D 9 0156 9 OTHERS 110D9CD109 ...

Page 102: ...1 73033CD49 R5573CD49 TRANSMISSION CONTROL UNIT TCU ENGINE CONTROL MODULE ECM MACHINE CONTROL UNIT MCU 3 4 5 The control unit is shifting the required speeds fully automatically under consideration of the following criteria Gear selector lever position Driving speed Load level The engine control module ECM is the control center of the engine system It consists of electronic parts and controls all ...

Page 103: ...MIC microphone 18 Aux connector FRONT PANEL PRESENTATION BASIC FUNCTIONS 1 Audio selection button Audio selection knob 2 Power and volume button 3 Mode button select RADIO USB AUX 4 UP DOWN tuning button 5 Preset memory button 1 DISP ID3 v2 display 6 Preset memory button 2 SCN File scan 7 Preset memory button 3 RPT Repeat play selector 8 Preset memory button 4 RDM Random play selector SEL MODE 1 2...

Page 104: ... automatically return to the normal indication in 5 seconds after the last adjustment or when another function is activated Treble control To adjust the treble level first select the treble mode by pressing the SEL button until TREBLE indication appears on the LCD display Within 5 seconds of choosing the treble mode turn selection knob right left to adjust the treble level as desired The treble le...

Page 105: ...s after the last adjustment or when another function is activated Loud control When listening to music at low volume levels this feature will boost the bass and treble response This action will compensate for the reduction in bass and treble performance experienced at low volume To select the loudness feature press SEL button until LOUD ON or LOUD OFF is displayed then turn selection knob left or ...

Page 106: ... buttons shortly will recall your favorite pre set radio stations To store your favorite stations into any of the 6 pre set memories in each band AM FM LW use the following procedure Turn the radio ON and select the desired band Select the first station to be pre set using the manual up down or automatic seek tuning control button Press the chosen pre set button to store your selected station into...

Page 107: ...e set memories to your favorite sta tions activating the BSM tuning feature will erase those stations and enter the new ones This BSM feature is most useful when traveling in a new area where you are not familiar with the local stations BSM 290F3CD42 4 USB function Connect a USB device if you want to listen to MP3 file in a USB device It will automatically play MP3 file in the USB device and the L...

Page 108: ...or more than 3 seconds while playing MP3 file Turn right left the selection knob to search the directory Press the button when you find the wanted directory For example the directory search generally changes in two methods depending on the order of writing as follows Method 1 ROOT Dir01 Dir02 Dir03 Dir04 Dir05 Dir06 Dir07 ROOT Method 2 ROOT Dir01 Dir02 Dir05 Dir03 Dir06 Dir04 Dir07 ROOT If you wan...

Page 109: ...RPT button is pressed and held longer than 2 seconds the RPT mark will blink on the LCD dis play and play all files in the selected directory and will be repeated until the directory repeat mode is cancelled by pressing the repeat button again or by activating the scan or random functions RPT mark will disappear from LCD display 3 RPT 75793CD84 File scan SCN 6 During USB play press SCN button to p...

Page 110: ...nd play all files in directory randomly until the directory random mode is cancelled by pressing the random button again or by acti vating the scan or repeat functions RDM mark will disappear from LCD display 4 RDM 75793CD85 Directory down 9 Press D button briefly while playing MP3 The previous directory is located each time you press this button 5 D 75793CD86 Directory up Press D button briefly w...

Page 111: ...gnal strength reduces over distance the quality of sound perfor mance during phone calls and music playback may become poor if the distance between the radio and device widens It is recommended that the mobile phone or music player is kept inside the cab for best results As a bluetooth wireless connection can extend to 10 meters your bluetooth device may automatically connect to the bluetooth radi...

Page 112: ... bluetooth device for the correct procedure to connect to another bluetooth device Once the bluetooth pairing is complete automatic connection between mobile phone and the bluetooth radio is possible whenever the starting switch is switched ON The mobile phone must be set to automatically connect to the bluetooth radio to allow this automatic connection a b c d e f Connection method Press SEND but...

Page 113: ...g 2 LG 3 Apple 4 Motorola 5 EMPTY 6 EMPTY Table 2 1 Press SEND button to select BLUETOOTH mode Press SEL button SELECT PHONE will appear on the display Turn selection knob until SELECT PHONE is displayed When SELECT PHONE appears on the display press SEL button Press the preset button to display the name of the bluetooth device name of the mobile phones or music players previously paired You may a...

Page 114: ...show previ ous paired phone name Samsung and DISCONNECTED In the example above the number of paired devices is now reduced to 3 leaving 3 vacant memo ry locations for additional devices Table 2 2 shows the example h i j Preset No Bluetooth device name for example 1 LG 2 Apple 3 Motorola 4 EMPTY 5 EMPTY 6 EMPTY Table 2 2 Basic telephone operation Using the bluetooth radio for hands free calls When ...

Page 115: ...h radio and speakers Additionally the bluetooth radio supports the Audio Video Remote Control Profile AVRCP If your bluetooth mobile phone or music player supports this profile then it is possible to advance to the next track or replay previous tracks on using the buttons on the front of the bluetooth radio your truck Press MODE button until BT AUDIO is displayed When BT AUDIO appears on the displ...

Page 116: ...low When VOICE VOLUME appears on the display press SEL button to display the current level of the calling voice Turn selection knob right or left to adjust the calling voice volume as desired This is the level the calling voice volume will be set to each time the bluetooth radio is used after the stating switch is turned off and then on again After making your selection press SEL button to store t...

Page 117: ...jack socket USB Ear HP Indicator lamp 12V socket USB Ear HP Mobile phone storage box 300D9CD51 21093CD51A 1 Mobile phone can be stored when call by handsfree HANDSFREE OPTION 7 This socket is used to charging the mobile phone USB socket 2 This can be used protect you privacy calling by using ear phone The mobile phone must be connected handsfree jack socket Private call jack socket 3 USB Ear HP 21...

Page 118: ... Connect the jack cable when call by handsfree Use the special adapter when jack cable is not interchangeable Check the jack type of mobile phone before use This lamp is turned ON when the handsfree mode selected Indicator lamp 5 USB Ear HP 21093CD51E ...

Page 119: ...elect HYUNDAI and set connect with Bluetooth on the mobile phone Default password 0000 The Bluetooth pairing is made the LCD screen shows CONNECTED Once the Bluetooth pairing is made they will be automatically connected after 20 seconds when start key ON When you want to deactivate the pairing press and hold the button for more than 3 seconds then you can hear beep sounds twice and the function wi...

Page 120: ... or handsfree ON or OFF This switch is turned to right the handsfree volume is increased over 7 steps If it is turned to left volume will be decreased This switch adjust the audio volume when selected audio mode Power and volume switch 1 This button is to select the handsfree mode or audio mode Lamp ON Handsfree mode TEL MUTE displayed ON audio LCD Lamp OFF Audio mode Mode change button 2 This but...

Page 121: ...Turn a station of higher frequency and the next song of the MP3 Turn a station of lower frequency and the previous song of the MP3 Mute button Short press this button to mute or cancel the mute silence while broadcasting 6 Mode button 7 Press the mode button to select the desired mode Radio MP3 AUX The LCD displayed each mode This MIC transfers user voice to receiver of the call when making a call...

Page 122: ...ted Radio handsfree You can make a call to external worker without holding the radio by hand The radio is not installed to the truck 55I3CD31H Talk button The call is connected while pressing this button when TALK button is activated Unlike mobile phones when you want to talk through the radio you need to press the button Push to talk method While one is talking through the radio the other party c...

Page 123: ...justing the angle Upwards and downwards up to 7 swivels left and right up to 15 7 50D9CD211 No Symbol Name Description 1 LEFT Move the Menu left Lower the value 2 MENU ENTER Enter the OSD menu Choose the menu 3 RIGHT Move the Menu right Upper the value Sunshade LCD 7 OSD Buttons ...

Page 124: ...50D9CD204K Display one camera image on screen Press left or right key to change the camera channel Display two camera images on screen Press left or right key to change the camera channel Display four camera images on screen Rear Front Side 1 Side 2 Rear Front Rear Side 1 Rear Side 2 Front Side 2 Front Side 1 Front Rear Rear Front Side 1 Side 2 ...

Page 125: ...setting Language 2 3 4 50D9CD205 50D9CD207 50D9CD209 50D9CD206 50D9CD208 50D9CD210 Depending on the gear state forward backward camera channel is switched automatically Adjust the display brightness Set the language 13 multiple language ...

Page 126: ... truck wear safety glasses and do not check for leaks with bare hands VISUAL CHECKS First perform a visual inspection of the truck and its major components Walk around your lift truck and take note of obvious damage that may have been caused by operation during the last shift Check that all capacity safety and warning plates or decals are attached and legible Check before and after starting engine...

Page 127: ...ator lights Service brakes inching pedal and parking brake Hydraulic controls lift tilt and auxiliary If installed Accelerator pedal Gear selector lever Steering system Lift mechanism and any attachments When the functional check are completed follow the standard shutdown procedures given in Section 5 Starting and operating procedures CONCLUDING THE INSPECTION Do not operate a lift truck that has ...

Page 128: ...ularly the lubrication and fill Grease daily all lubrication points Tighten bolts Warm up the truck fully before operation Check the gauges during operation Check if the truck is operating normally during operation Replace following after initial hours of operation 4 Avoid excessive operation for initial 100 hours 2 SUGGESTION FOR NEW TRUCK 1 2 ö 3 1 2 3 4 5 6 110D9OP01 Service meter Load Until 10...

Page 129: ...hall be kept at a safe distance while refueling 100D7OM106 D35AOM106 USE CLEAN PROPERLY MARKED FUEL CANS CLEAN UP SPILLS D35AOM106 DANGER DIESEL FLAMMABLE D35AOM106 Make sure that the fuel oil cans are kept cleaned and attached safety indication or letters on the can Wipe off the spilt fuel oil immediately ...

Page 130: ...ions or attachments from any place other than the designated operator s position Inspect your lift truck before operating at the start of each shift Before putting your truck to use check the operation of the controls and all systems Protect yourself Do not operate truck without closing the cabin door or without fastening seat belt unless conditions prevent its use Use special care if operation wi...

Page 131: ... your personal safety and to realize maximum service life for your truck The numbers on the inspection chart show the order of inspection These numbers correspond to the check item numbers given on the next pages Hang a caution sign on the truck for example Do not start or maintenance in progress This will prevent anyone from starting or moving the truck by mistake 2 1 Oil leakage 2 Tire air press...

Page 132: ... tires and rims could cause the tire to explode causing serious injury or damage The tires and rims should always be serviced or changed by trained personnel using the correct tools and procedures For details of procedures contact your HYUNDAI dealer or tire repair shop If there is any deformation damage or wear of the rim or any doubt about the condition always replace the rim Never try repairing...

Page 133: ...ompletely empty first add water directly to the surge tank Then add water to the reservoir tank Alway allow the radiator to cool down before adding water At the operating temperature the engine cooling water is at high temperature and pressure so it is dangerous to try to open the surge tank cap Wait until the radiator is cool enough to be touched by hand before opening the surge tank cap Loosen t...

Page 134: ...ion of belt ribs cracks that intersect with transverse cracks are not acceptable Inspect the belt Embedded debris Uneven excessive rib wear Exposed belt cords Glazing high heat If any of the above conditions are present the belt is unacceptable for reuse and must be replaced 1 2 OK NOT OK 120096MA42 120096MA43 2609A6MA47 Η Θ Ι ö CHECK BATTERY Check battery and recharge or replace the battery if ne...

Page 135: ...kin 1 Normal Dipstick L H 160D7AOM112 CHECK HYDRAULIC OIL LEVEL 8 Rest fork on ground and stop engine Check the oil level from the level gauge of hydraulic oil tank In accordance with the mast equipped the oil level differs 1 2 3 Upper limit Level gauge Lower limit 160D7MA14 Model Gauge U S gal V mast TF mast 110D 9 130D 9 Lower limit 159 42 3 V300 700 TS395 750 Upper limit 172 45 4 VS300 600 160D...

Page 136: ...d in the tank If the level of the washer liquid is LOW add the washer liquid In cold winter days or water The capacity of the tank is 1 liter 1 Η Θ Ι ö MULTI FUNCTION SWITCH 10 O J Ɇ ɇ 73033CD29 Turning switch This switch is used to warn or signal the turning direction of the truck to other vehicles or equipment Push the lever up for turning left pull the lever down for turning right Dimmer switch...

Page 137: ...e oil level is below the plug hole supply oil through the plug hole Set the plug of planetary gear in parallel to the ground When checking the oil level place the parking brake switch in the LOCK position and fix the tires with blocks As the truck is hot after operation wait until the temperature has dropped The DEF AdBlue tank level must be checked daily with DEF AdBlue level gauge If the DEF AdB...

Page 138: ...urs of the operator s body It will reduce operator fatigue due to long work hours and enhance work efficiency Forward Backward adjustment Pull lever A to adjust seat forward or backw ard The seat can be moved forward and backw ard over 200 mm 8 in in 10 steps Upward Downward adjustment Pull lever B and C to adjust seat upward or downward Forward or backward side adjustment only can be made tilting...

Page 139: ...l the controls function All controls are in neutral or other correct position The truck has received its daily inspection and ready and safe to operate 1 Â Â Â Â Â Â Â Put the gear selector lever in the NEUTRAL position before starting The truck should start only in the NEUTRAL position If it starts in gear have the truck serviced 2 LOCK Forks are down Parking brake switch 110D9OM31 Forward Backwa...

Page 140: ...peed to approximately half throttle for a short period or until the engine coolant reaches approximately 38 C 100 F This procedure helps prolong engine life Let the engine run until the normal operating temperature is reached Then operate the controls and check all gauges and warning indicators to be sure they are functioning properly Stop the engine and make a visual inspection for oil water or f...

Page 141: ... lamp 3 Start the engine after all of the lamps OFF Only above 3 lamps remain ON 1 2 3 Η ö Θ ö 7 STARTING AND STOPPING THE ENGINE 1 1 3 2 Gear selector lever Parking brake switch 110D9OP03 STARTING ENGINE IN NORMAL TEMPER ATURE Sound the horn to warn the surroundings after checking if personnel or obstacles are in the area Turn the starting switch to START position to start the engine If the engin...

Page 142: ...g condition after starting the engine Travelling the truck or operation of the attachments could be caused shut down of the engine In the event of the winter season the fuel oil happens WAX from 6 C When the ambient temperature is below 6 C do not operate the truck under high load condition so that it can operate normally the fuel system of the engine and operate the truck after keeping idle condi...

Page 143: ...lem as required Η Θ Ι Κ ö ö Check engine exhaust color 5 Check fuel tank level 6 Colorless light blue Black White Exhaust gas color Criteria OK Check for incomplete combustion Check for oil leakage If the indicator points to F the tank is full If the indicator enters the E range refill the fuel tank immediately Do not operate the truck below this level Do not use low quality fuel or fuel mixed wit...

Page 144: ...on the lift chain Do not put hands into the mast Η Θ SEAT BELT WARNING LAMP ENGINE CHECK WARNING LAMP FUEL LOW LEVEL WARNING LAMP T M OVERHEAT WARNING LAMP E G COOLANT OVERHEAT WARNING LAMP SCR CLEANING WARNING LAMP DEF LOW WARNING LAMP WARNING LAMP ENGINE STOP E G OIL PRESSURE WARNING LAMP WATER IN FUEL WARNING LAMP BRAKE OIL PRESSURE WARNING LAMP BRAKE OIL TEMPERATURE WARNING LAMP T M ERROR WARN...

Page 145: ...TRAL 1 2 3 4 5 TO STOP THE ENGINE If the engine is abruptly stopped before it has cooled down engine life may be greatly shortened Consequently do not abruptly stop the engine apart from an emergency In particularly if the engine has overheated do not abruptly stop it but run it at medium speed to allow it to cool gradually then stop it Place the gear selector lever in neutral Place the parking br...

Page 146: ...d up the idling and run the engine at mid range speed Lift the forks slightly and tilt the mast forward to the stroke end to relieve hydraulic pressure Do not leave hydraulic pressure relieved for more than 30 seconds Tilt back to the stroke end to relieve hydraulic pressure Do not leave hydraulic pressure relieved for more than 30 seconds Repeat the procedure 3 4 several times until warm up opera...

Page 147: ...e other conditions that may affect stability are ground and floor conditions grade speed loading dynamic and static forces and the judgement exercised by the operator Trucks equipped with attachments behave as partially loaded trucks even when operated without a load on the attachment Also improper operation faulty maintenance or poor housekeeping may contribute to a condition of instability For s...

Page 148: ... Use the inching pedal and the accelerator pedal in combination to vary lift and travel speeds independently The further you depress the inching pedal the more the driving clutch slips reducing travel motion With the inching pedal fully depressed the brakes fully engage You operate the inching pedal with your left foot for precise control of travel speed while you operate the accelerator pedal tog...

Page 149: ...ove the truck Η Θ Changing direction and speed The gear selector lever is designed for the mounting on the left side of the steering column The positions speeds 1 to 3 are selected by a rotary motion the driving direction Forward F Neutral N Reverse R by tilting the gear selector lever A neutral lock is installed as protection against inadvertent drive off ÂPosition N Gear selector lever blocked i...

Page 150: ...th engine OFF Precautions when driving If the monitor warning lamp lights up put the gear selector lever in the neutral position and stop the truck Stop the engine after running it at low idling Then resolve any problems regarding operation of the truck When operating the truck if the load is lighten rapidly the speed of the truck will increase So be careful When the truck travels on uneven ground...

Page 151: ...ling for 5 minutes Stopping the truck Press the brake pedal to stop the truck Put the gear selector lever in the neutral position Put the parking brake switch in LOCK position 6 Gear selector lever Parking brake switch 110D9OP14 110D9OP07 Η Θ Ι ...

Page 152: ...heck the leakage of oil and water the work equipment and the exterior of the truck Refill the fuel tank Remove any debris inside of the engine room and attached to the truck 7 ö ö Η Θ Ι 8 Η Θ Ι 5 minute warming up Parking brake switch Gear selector lever 110D9OP20 TRAVELING ON A SLOPE Never travel down a slope in neutral Lower the forks 15 20 cm 6 8 in to the ground Never turn on a slope either lo...

Page 153: ...act Therefore it should not be considered a substitute for good judgement and care in loading handling storage etc Keep clear of the mast and lift mechanism NEVER reach into or put hands arms legs or head into or through the mast structure or near the carriage or lift chains Never put any part of your body between the mast and the truck Don t use the mast as a ladder Keep all other persons clear o...

Page 154: ...n and stay during 10 minutes with engine idle speed Do not travel down incline with neutral gear state It makes the brake oil overheated due to excessive brake operation PRACTICE SAFE OPERATION EVERY TIME YOU USE YOUR TRUCK Careful driving and operation is your responsibility Be completely familiar with all the safe driving and load handling techniques in this Operator s Manual Use common sense Dr...

Page 155: ... mast vertical or tilted slightly back never tilted forward Operate lift and tilt controls slowly and smoothly Never tilt the mast forward when the carriage load is raised except to pick up or deposit a load over a rack or stack Slack chains mean rail or carriage hang up Raise the mast before you move If the mast malfunctions in any way or becomes stuck in a raised position operate the lift contro...

Page 156: ... easier Unlock the fork locking pins Position the forks by pushing them away from you Secure the fork locking pins 2 160D7OM134 LOAD ON FORKS Do not elevate the load with one fork Loading with one fork cause the tip over serious injury or death of operator The work can cause the height difference between both fork tips 1 3 110D9OM137 Do not elevate the load with the ends of the forks This work can...

Page 157: ...ible Use special care when handling and traveling with long high or wide loads to avoid losing the load striking bystanders or obstructions or tipping the truck Watch clearances around the truck and load as you travel Raise the forks or attachment only to pick up or stack a load Look out for obstructions especially overhead Be aware that exaggerated tail swing when turning while traveling forward ...

Page 158: ...oad without extending beyond the load Raise the load to clear the ground Back out several inches or whatever distance is necessary then set the load down and move forward until the load is positioned against the carriage Raise the load from the ground or stack by tilting the mast back just enough to lift the load from the surface When stacking or tiering use only enough backward tilt to stabilize ...

Page 159: ...high enough to clear the top of the stack Slowly move the load into position Use care not to damage or move adjacent loads When the load is aligned with the stack beneath it tilt the mast to the vertical position and carefully lower the load onto the top of the stack Κ Λ Lower the forks slightly to clear the load pallet Tilt the forks forward slightly if necessary Μ D35AOM137 D35AOM138 D35AOM139 D...

Page 160: ...hen set the load down and move forward until the front face of the forks contacts the load Be careful that the fork tips now clear the adjacent load or material behind the load being moved Raise the load from the stack by tilting the mast back just enough to lift the load from the surface Or with the mast still vertical raise the forks until they begin to lift the load At this point apply the mini...

Page 161: ...ays and fire equipment ö 1 2 1 2 3 1 2 3 4 LOCK Forks are down Parking brake switch 110D9OM31 Low idling for 5 minutes 110D9OP07 IN ADDITION WHEN LEAVING THE TRUCK UNATTENDED Tilt the mast forward until the forks are level and flat on the ground Let the engine run at idle speed Turn the start switch to the OFF position and remove the key Block the wheels if the truck must be left on an incline or ...

Page 162: ...A 6 Steering axle 5EA 7 Hyd pump drive spline 1EA 7 110D9OP17 1 1 2 3 4 5 6 ö DURING STORAGE Operate the engine and move the truck for a short distance once a month so that a new oil film will be coated over movable parts and component surfaces Remove and storage the battery at the same time The above operations should be performed in the open If they have to be performed inside a building open th...

Page 163: ...the loading dock Ensure that the transporter cannot move by applying the brake and putting blocks under the wheels Put the gear selector lever in the NEUTRAL position Fix the loading ramps securely so that the centers of the transporter and truck are aligned The loading ramps should be of sufficient width length and thickness to permit safe loading or unloading After checking that the truck is ali...

Page 164: ...cification of the truck when you are going to hoist the truck Use long wire rope and stay to keep the distance with the truck as it should avoid touching with the truck body Put a rubber plate where the wire rope contact with the truck s body to prevent damage Place crane on the proper place Install the wire rope and stay like the illustration Make sure wire rope is proper size Make sure that the ...

Page 165: ...with a chain Obtain another lift truck of equal or larger size carrying a partial load for traction Check that the counterweight bolts are in place and properly torqued This bolt is made of a special high tensile steel and is not commercially available Replace it when necessary only with a genuine HYUNDAI replacement part Use an approved solid metal tow bar with towing couplers that connect to the...

Page 166: ... personnel near it Park the disabled truck in authorized areas only Fully lower the forks to the floor put the gear selector lever in the NEUTRAL position and turn the staring switch to the OFF position Set the parking brake switch ON position Remove the start switch and when necessary block the wheels to prevent the truck from rolling 9 ...

Page 167: ...be secured against rolling away Release the screw cap 4 and unscrew Release the lock nut 5 and turn the adjusting screw 3 with socket wrench size 8 or 10 manually counter clockwise until the brake disc is free For the emergency release is an actuation torque of 40 Nm respectively 70 Nm required Mount the lock nut 5 and the screw cap 4 and tighten both as far as possible manually protection against...

Page 168: ... Be sure to install the caps before jump starting Do not jump start charge or test a sealed type battery if the test indicator looks illuminated or has a bright color Install a new battery BATTERIES EMIT EXPLOSIVE GAS Do not smoke or have open flames or sparks in battery charging areas or near batteries An explosion can result and cause injury or death Hydrogen gas is produced during normal batter...

Page 169: ...ys fans or other parts that move Do not touch hot manifolds that can cause sever burns Start the engine on the jumper truck and run the engine at a moderate speed for a minimum of five minutes Start the engine on the stalled truck Follow the starting instructions in section 5 Starting and Operating Procedures in this manual Be sure that the engine is at idle speed before disconnecting the jumper c...

Page 170: ...n HYUNDAI recommends that the owner set up and follow a periodic planned maintenance PM and inspection program Performed on a regular basis by trained personnel the program provides through truck The PM identifies needed adjustments repairs or replacements so they can be made before failure occurs The specific schedule frequency for the PM inspections depends on the particular application and lift...

Page 171: ...ifications Always wear safety glasses Wear a safety hard hat in industrial plants and in special work areas where protection is necessary and required Properly ventilate work area vent exhaust fumes and keep shop clean and floors dry Avoid fire hazards and have fire protection equipment present in the work area Do not use an open flame to check for level or leakage fuel electrolyte or coolant Do n...

Page 172: ...s valves and other parts must be checked to assure that drift or leakage has not developed to the extent that it would create a hazard When working on the hydraulic system be sure the engine is turned off mast is in the fully lowered position and hydraulic pressure is relieved in hoses and tubing Always put oak blocks under the carriage and mast rails when it is necessary to work with the mast in ...

Page 173: ...edures Always use genuine HYUNDAI or HYUNDAI approved parts When removing tires follow industry safety practices Most importantly deflate pneumatic tires completely prior to removal Following assembly of tires on multi piece rims use a safety cage or restraining device while inflating Use special care when removing heavy components such as counterweight mast etc Be sure that lifting and handling e...

Page 174: ... ware houses The indicated intervals are intended for normal operation The operating condition classifications are NORMAL OPERATION Eight hour material handling mostly in buildings or in clean open air on clean paved surfaces SEVERE OPERATION Prolonged operating hours or constant usage EXTREME OPERATION In sandy or dusty locations such as cement plants lumber mills and coal dust or stone crushing ...

Page 175: ...e of truck Use Hyundai genuine parts Use the recommended oil Remove the dust or water around the inlet of oil tank before supplying oil Drain oil when the temperature of oil is warm Do not repair anything while operating the engine Stop the engine when you fill the oil Relieve hydraulic system of the pressure by opening of breather when repairing the hydraulic system Confirm if the cluster is in t...

Page 176: ...Tilt cylinder hose Every 1 to 2 years 8 Side shift cylinder hose Every 1 to 2 years 9 Master cylinder and wheel cylinder caps dust seals Every 1 years 10 Brake hose or tube Every 1 to 2 years 11 Brake reservoir tank tube Every 2 to 4 years 12 Intake air line Every 2 years 13 Coolant hose and clamps Every 2 years EMISSION RELATED COMPONENTS WARRANTY USA AND CANADA ONLY Hyundai shall have obligation...

Page 177: ...ission 10 Torque converter 11 Engine 12 Steering cylinder 13 Hydraulic pump 14 Steering axle 15 Rear wheel 16 Air cleaner 17 Counterweight 18 Radiator 19 Seat 20 Cabin 21 Steering wheel 22 Silencer 23 Drive shaft 24 Precleaner 25 Aftertreatment device 16 7 8 20 19 23 9 10 11 15 12 14 22 17 18 13 21 1 2 3 6 5 4 24 25 110D9OM21 MAJOR COMPONENTS LOCATION 1 ...

Page 178: ...k Repair or Replace Check Repair or Replace Check Repair or Replace Check Repair or Replace Check Replace Check Repair or Replace Check Repair or Replace Check Repair or Replace 7 15 7 15 7 17 7 57 7 45 3 6 5 13 3 8 7 20 7 22 3 9 7 28 7 34 5 5 7 31 4 2 7 53 4 2 7 53 4 2 7 53 4 2 7 53 4 2 7 54 10 4 7 55 7 55 5 13 Check items Service Remarks Transmission oil level Hydraulic tank air breather element...

Page 179: ... Lift chain Mast roller and pin Lift cylinder rod end Lift cylinder tube end Tilt cylinder rod end Tilt cylinder tube end Steering cylinder rod end Steering cylinder tube end Attachment option cylinder rod end Attachment option cylinder tube end Steering axle wheel bearing Pedal pivot Check Add Check Clean Check Add Check Replace Check clean Check clean Check Lubricate Check Lubricate Check Lubric...

Page 180: ...Brake cooling oil strainer Pilot line filter element Air conditioner outer filter Replace Replace Change Replace Change Check Replace Change Replace Replace Replace 7 27 7 35 7 40 7 43 7 26 7 45 7 45 7 36 7 48 Check items Service Remarks Hydraulic tank suction strainer Radiator coolant Hydraulic oil 2 Crankcase breather filter Hoses fittings clamps fuel coolant hydraulic Replace Replace Replace Re...

Page 181: ...d exhaust system ÂAir cleaner element ÂDEF level Hydraulic tank ÂHydraulic oil ÂHydraulic oil suction strainer ÂReturn oil filter element ÂAir breather element Hand pump cabin tilt ÂHydraulic oil Tire air pressure Drain or Clean Check Drain Replace Change Replace Add Change Clean Replace Check Refill Add or Change Check Clean Replace Replace Add or Change Check Add 7 28 7 28 7 29 7 20 7 20 7 22 7 ...

Page 182: ...Do not open the cap or drain plug to avoid injury by unexpected spouting of high temperature fluid or gas Open the cap slowly to relieve pressure Always keep the surface of control instrument panels clean in case of damage or malfunction detected in panel please it by a new one For other details refer to the service manual MAINTENANCE LOCATIONS 1 ö ö ö ö ö ö 5 MAINTENANCE CHART CAUTION ...

Page 183: ...Hydraulic pump device Check Lubricate G 1 Initial 100 Hours 1 Axle gear oil Change GO 19 3 6 Transmission oil Change EO 16 1 10 Brake cooling oil Change BO 22 1 18 Transmission oil filter Replace 1 250 Hours or monthly 1 Axle gear oil Check Add GO 19 3 10 Brake cooling oil Check Add BO 22 1 15 Lift chain Check Lubricate EO 2 16 Tilt pin Mast roller Check Lubricate G 2 23 Hydraulic tank air breathe...

Page 184: ...and any safety devices are in place undamaged and attached securely Check the cabin for damage Be sure that it is properly positioned and all mounting fasteners are in place and tight LOAD HANDLING COMPONENTS Inspect the mast assembly load backrest rails carriage rollers lift chains and lift and tilt cylinders Look for obvious wear and maintenance problems and damaged or missing parts Check for an...

Page 185: ...0 mm 24 in carpenter s square on the top of the block and against the shank Check the fork 500 mm 20 in above the metal block to make sure it is not bent more than 12 5 mm 0 5 in maximum If the fork blades are obviously bent or damaged have them inspected by a trained maintenance person before operating the truck Inspect the fork locking pins for cracks or damage Reinsert them and note whether the...

Page 186: ...uts Torque loose or replaced items to specifications Check tire pressure from a position facing the tread of the tire not form the side Use a long handled gauge to keep your body away from the side If tires are low do not operate and do not add air Check with a mechanic The tire may require removal and repair Incorrect low tire pressure can reduce the stability of your lift truck Do not operate tr...

Page 187: ...d It is recommended that the service requiring tilting cabin must be carefully performed with a skilled service man Tilting and returning cabin Refer to page 3 32 for the cabin tilt switch and hand pump lever Tilting cabin After keeping clearance of the people except the operator along with sounding horn turn the hand pump lever clockwise and then continuously press the cabin tilt switch to tilt t...

Page 188: ...9MI64 110D9MI66 Fill and check hydraulic oil for hand pump Open upper cap and fill 0 8 by using funnel After filling operate tilt cylinder 2 3 times and close the cabin completely to check the oil level in tank If necessary fill more oil to keep the level ÂTank capacity 0 7 ÂSystem total capacity 1 2 5 Do not operate cabin tilting function while the power is ON or engine is running Drain Reservoir...

Page 189: ...he oil level is in the normal range Normal Dipstick Dipstick Oil drain plug Engine oil filter Clean around the filter head remove the filter by the filter wrench and clean the gasket surface The O ring can stick on the filter head Be sure it is removed before installing the new fil ter 7 SERVICE INSTRUCTION 1 1 2 3 侍侍 290F6MA01 2609A6MA04 110D9MA06 3 侍 REPLACEMENT OF ENGINE OIL AND OIL FILTER War...

Page 190: ...e engine off and check the oil level with the dipstick Allow 15 minutes for oil to drain down before checking Fill the engine with clean oil to the proper level ÂQuantity 14 2 3 7 U S gallons 2609A6MA07 160D7A6MA08 2609A6MA09 160D7A6MA10 5 侍 6 7 Apply a light film of lubricating oil to the gasket sealing surface before installing the filter Fill the filter with clean lubricating oil The lack of lu...

Page 191: ...idance as to proper handling of used antifreeze 4 1 侍 A B FULL LOW 2 1 CHECK COOLANT LEVEL Check the coolant level at reservoir tank when the engine is cooled Add the mixture of antifreeze and water after removing the cap of the reservoir tank if coolant is not sufficient The coolant level should indicate between FULL and LOW Replace gasket of surge tank cap when it is damaged Do not remove the su...

Page 192: ...nd water or a commercially available equivalent Use 0 5 kg 1 0 pound of sodium carbonate for every 23 liters 6 0 U S gallons of water Do not install the surge tank cap The engine is to be operated without the cap for this process During filling air must be vented from the engine coolant passages The system must be filled slowly to prevent air locks or serious engine damage can result Wait 2 to 3 m...

Page 193: ...he system has a maximum fill rate of 19 liters 5 0 U S gallons per minute Do not exceed this fill rate The system must be filled slowly to prevent air locks During filling air must be vented from the engine coolant passage Cooling system filling Use a mixture of 50 percent water and 50 percent ethylene glycol antifreeze to fill the cooling system Refer to the page 7 62 Coolant capacity engine only...

Page 194: ...air pressure to blow the dirt and debris from the fins Blow the air in the opposite direction of the fan air flow Visually inspect the radiator for bent or broken fins If the radiator must be replaced due to bent or broken fins which can cause the engine to overheat refer to the manufacturer s replacement procedures Visually inspect the radiator for core leaks NOT OK 550 kPa 80 psi 160D7A6MI01 160...

Page 195: ...contact with the spring case stop the tensioner must be replace Check the location of the drive belt on the belt tensioner pulley The belt should be centered on or close to the middle of the pulley Misaligned belts either too far forward or backward can cause belt wear belt roll offs or increase uneven tensioner bushing wear 2609A6MA25 2609A6MA26 3 侍 4 With the belt installed verify that neither t...

Page 196: ...ter is needed If there is any dam age to the filter body gaskets or endplates do not clean or reuse the filter should be discard ed Always clean filters in a clean environment observe strict inspection procedures and repackage filters immediately after the clean ing process with appropriate materials Use observe proper safety precautions and dispose of waste materials in an environmen tally compli...

Page 197: ...e water Close drain valve Don t tighten up a drain valve so strong Please inspect and drain water frequently for remain water volume to be less than 1 3 volume of a collection bowl Bowl Drain valve Open Close 10 1 侍 35D9F6MI20 Η Θ ö ö Replace element Loosen the air vent plug and drain the fuel of the unit Follow Drain water instructions above Remove element and bowl from filter head The bowl is re...

Page 198: ...t the outlet of prefilter Do hand priming the lift pump repeatedly until air bubbles comes out from air vent plug hole completely Tighten air vent plug to its origin position The fuel pump high pressure fuel lines and fuel rail contain very high pressure fuel Do not loosen any fittings while the engine is running Personal injury and property damage can result Wait at least 10 minutes after shuttin...

Page 199: ...indicates proper engagement with the filter If the filter element and equalizing element are removed from the aftertreatment DEF dosing unit they must be discarded and replaced regardless of condition 13 1 ö Η 刯到 Κ ö 1 2 3 250D9DEF01 290F6MA60 1 DEF dosing unit filter cap 2 DEF filter equalizing element 3 DEF dosing unit filter element Clean and inspect for reuse Inspect the aftertreatment DEF do...

Page 200: ...rtreament DEF dosing system will not prime until the correct SCR temperatures are reached To verify that there are no DEF leaks test drive the truck for a minimum of 15 mimutes to get the SCR system up to temperature Η 刯到 ö ö 1 2 3 250D9DEF04 1 DEF dosing unit filter cap 2 DEF filter equalizing element 3 DEF dosing unit filter cartridge 3 DEF AdBlue TANK The DEF AdBlue tank level must be checked ...

Page 201: ...ap screws Remove the filter cover Cap Cover Capscrew 15 侍 7609A6MI30 1 2 3 Remove the crankcase breather filter from the rocker lever cover Do not disturb the crankcase breather filter gasket located on the rocker lever cover Exposure to oil can cause the gasket to swell which can make it difficult to install the gasket back into groove If the gasket comes out of the groove do not attemp to instal...

Page 202: ...nto the groove Do not cut the gasket to make it fit into the groove as this will result in an oil leak The gasket must be fully seated around the entire perimeter of the rocker lever cover groove 1 5 2 3 4 7609A6MI28 8 侍 Apply clean engine oil to the O rings on the crankcase breather filter Install the filter onto the rocker lever cover 7609A6MI29 9 Install the crankcase breather filter cover Inst...

Page 203: ...o the page 5 6 for details 17 1 2 3 ö ö 110D9MI21 LEAKAGE OF FUEL Be careful and clean the fuel hose injection pump fuel filter and other connections as the leakage from these part can cause fire FIRE 16 80D96MA07 FILLING HYDRAULIC OIL Stop the engine to the position of level check Check air breather element and replace it if necessary Loosen cap and fill the oil to the specified level Start engin...

Page 204: ...bles are present in the oil air is entering the hydraulic system Inspect the suction hoses and hose clamps for leakage or damage Cap Air breather Drain pan Drain plug 19 1 2 3 4 5 6 7 ö 110D9MI19 CLEAN SUCTION FILTER AND REPLACE RETURN FILTER Clean and replace the return filter in the following manner Remove the flange by loosening the mounting bolt Remove the return filter from the tank Replace t...

Page 205: ...ent Valve Case O ring Line filter assy REPLACE OF PILOT LINE FILTER Loosen the filter case Pull out the filter element and clean the filter case Replace the filter element and O ring with new parts Reassemble the line filter 22 1 2 3 4 160D9MI23 CLEANING BRAKE LINE FILTER Remove the strainer from the filter body Wash the strainer with cleaning oil Install and tighten with specified torque ÂTighten...

Page 206: ...r overinflated The three major causes for excessive heat and pressure of tire are insufficient pressure excessive load and overspeed Avoid excessive load and overspeed in order to keep tires in good shape Do not inflate tires using flammable gases or alcohol injector This cause explosion or personal injury Inflate tires at the pressure level recommended by the manufacturer and check periodically p...

Page 207: ...ion Η Θ Ι Κ ö Tread Valve Side wall Carcass Bead REPLACEMENT OF TIRE Disassembly reassembly replacement and repair of tire requires special skills and equipment Contact a tire repair shop Tires to be replaced Tires with broken or bent bead wires Tires exposed more than 1 4 of carcass fly Tires whose carcass is damaged more than 1 3 of the tire width Tires which show fly separation Tires which has ...

Page 208: ...tighten torque ÂTightening torque 83 2Ü10 0 kgfÂm 602Ü72 3 lbfÂft 1 2 3 4 5 6 7 8 9 10 4 Η Θ Ι STORING TIRES AFTER REMOVAL As a basic rule store the tires in a warehouse which unauthorized persons cannot enter If the tire are stored outside always erect a fence around the tires and put up No Entry and other warning signs that even young children can understand Stand the tire on level ground and bl...

Page 209: ...ull it out again On the oil level gauge the oil level must be lying in the zone HOT Insert the oil level gauge again and tighten it by clockwise rotation When checking put the parking brake switch in the LOCK position and fix the tires with blocks HOT COLD ZONE HOT Level gauge REPLACEMENT OF TRANSMISSION OIL AND FILTER ELEMENT Operate the truck for a few minutes in order to warm the transmission o...

Page 210: ... Screw the filter in until contacts with the sealing surface is obtained and tighten it now by hand about 1 3 to 1 2 turn Mount the drain plug of the transmission after cleaning it Fill the oil through the level gauge inlet and check if the oil is at the appropriate level The proper oil amount is 16 liters 4 2 U S gallons As the truck is hot after operation wait until the temperature has dropped I...

Page 211: ...ning oil Air breather CHECK AND SUPPLYING AXLE OIL Move the truck to flat ground Open the axle air breather to relieve internal air pressure Air breather Remove the plug and check the oil amount If the oil level is at the hole of the plug it is normal Fill oil level plug Differential gear 30 1 2 31 1 2 3 110D9MI45 110D9MI46 110D9MI47 ...

Page 212: ... should be facing the ground HORIZ OIL FILL LEVEL DRAIN Planetary gear After draining put the drain plug of planetary gear in parallel to the ground HORIZ OIL FILL LEVEL DRAIN Planetary gear Planetary gear HORIZ OIL FILL LEVEL DRAIN Plug 32 1 2 3 Η Θ 4 Η ö 5 110DEMI48 110DEMI50 110DEMI51 110D9MI49 If the oil level is below the plug hole supply oil through a plug hole When checking the oil level en...

Page 213: ... after operation wait until the temperature has dropped If a work requires frequent use of brake replace it earlier than normal change interval Fill oil level plug Differential gear HORIZ OIL FILL LEVEL DRAIN Planetary gear CLEANING AXLE BREATHER Remove dust or debris around the breather Remove the breather and wash it with a cleaning oil Air breather 6 7 ö 33 1 2 110D9MI52 110D9MI46 ...

Page 214: ... rear tires with blocks Set the mast and forks in a stable position 1 2 35 BRAKE COOLING OIL AND STRAINER Check the oil level If oil level is near or under the lower limit add oil immediately Change oil and strainer completely every 1000 hours operation Plug Strainer Cap Axle cooling oil reservoir tank Frame RH side 34 1 2 3 110D9MI60 Η Θ Ι Κ Λ Μ Ν Hanger bar Fork retainer Cover Bolt 100D7MS07 FOR...

Page 215: ...ning Dust seal are mounted on the rotating part of working device to extend the lubricating interval Mount the lip to be faced out side when replace the dust seal If it is assembled in wrong direction it will cause fast wear of pin and bushing and create noise and vibration during operation Make sure the seals are not damaged or deformed 37 1 2 3 ö 4 ö ö ö WORK EQUIPMENT SUPPORT When carrying out ...

Page 216: ... out any electric welding on the truck the battery cables should be disconnected and the connectors pulled out of the electronic control units MCU ECM TCU cluster etc Connect the earth ground lead of the welding equipment as close to the welding points as possible Do net weld or flame cut on pipes or tubes that contain flammable fluids Clean them thoroughly with nonflammable solvent before welding...

Page 217: ...MI50 When using the air conditioner for a long time open the window once every one hour Be careful not to overcool the cab The cab is properly cooled if the operator feels cool when entering there from outside About 5 C lower than the outside temperature When cooling change air occasionally CHECK DURING SEASON Ask the service center for replenishment of refrigerant or other maintenance service so ...

Page 218: ... warming Do not release refrigerant into the environment Safety precautions Work on the air conditioning system must only be performed by a qualified service technician Do not attempt to preform work on the air conditioning system Wear safety goggles chemical resistant gloves and appropriate personal protective equipment to protect bare skin when there is a risk of contact with refrigerant Action ...

Page 219: ...lectrolyte in eyes Wash with clean water and go to the doctor if it enters the eyes 1 1 2 2 Recycle Recycle Never discard a battery Always return used batteries to one of the following locations A battery supplier An authorized battery collection facility Recycling facility 2 2 3 3 When remounting connect the ground connection last Do not allow tools to touch the terminal and Do not allow tools to...

Page 220: ...medangerous to use it Do consult an expert about this matter when you are not able to about this matter when you are not able to judge its condition It is strongly recommended judge its condition It is strongly recommended to keep the surroundings of the battery cables to keep the surroundings of the battery cables clean so that the machine can be freed from the clean so that the machine can be fr...

Page 221: ...n jacking up the truck never go under the truck For wheels using a separate type rim check first that the rim nut is not loose before loosening the lug nuts Be careful not to mistake the rim nuts and lug nuts When assembling separated type rims with bolts and nuts check any damage and tighten them to the specified tightening torque Change the bolts and nuts with new ones after using twice for your...

Page 222: ...inside to open the cover of the fuse box or relay box push the side of the cover lightly with a finger and pull the cover forward to remove it When replacing the fuse or relay check the relationship between the fuse or relay and the electrical components it protects Always replace fuses or relays with a same capacity Always turn the start switch OFF before replacing any fuse or relay Η Θ ...

Page 223: ...r meter Start the engine and let it warm up until it runs evenly and accelerates smoothly when you push on the accelerator pedal Check the hour meter for operation with the engine running Write the hour meter reading on the PM report form Report any malfunction or damage 1 2 6 Lamp Spec 24V Head lamp 70W Turn signal lamp LED Clearance lamp LED Stop lamp LED Backup lamp 10W License lamp option 10W ...

Page 224: ... Watch the mast as it lowers When the forks reach the floor release the lever All movements of the mast fork carriage and lift chains must be even and smooth without binding or jerking Watch for chain wobble or looseness the chains should have equal tension and move smoothly without noticeable wobble Auxiliary controls option If your lift truck is equipped with an attachment test the control lever...

Page 225: ...dal and put it on the accelerator pedal Push down until the truck moves slowly forward Remove your foot from the accelerator pedal and push down on the service brake pedal to stop the truck The brakes should apply smoothly and equally Be sure the travel area is clear behind the truck Put the gear selector lever in the REVERSE travel position Release the service brake and push down on the accelerat...

Page 226: ...on the truck Keep the truck free from leaking oil and grease Wipe up all oil spills Keep the controls and floorboards clean dry and safe A clean truck makes it easier to see leakage and loose missing or damaged parts and helps prevent fires A clean truck runs cooler The environment in which a lift truck operates determines how often and to what extent cleaning is necessary For example trucks opera...

Page 227: ...Do not piece chains together Lift chain inspection and measurement Inspect and lubricate the lift chains every 10 hours or daily and check tension every 250 hours or monthly When operating in corrosive environments inspect the chains every 50 hours During the inspection check for the following conditions Â Rust and corrosion cracked plates raised or turned pins tight joints wear and worn pins or h...

Page 228: ...h The distance from the center of one pin to the center of the next pin All chains must be replaced if any link has wear of 3 or more or if any of the damaged conditions notes above are found during inspection Order replacement chains from your HYUNDAI dealer Replace all chains as a set Do not remove factory lubrication or paint new chains Replace anchor pins and worn or broken anchors when instal...

Page 229: ... max 2 kgf cm2 30 psi Check the fan belt tension If it is too slack adjust the tension refer to the page 5 5 In case of overheating do not stop the engine immediately Run the engine at low idling Open the hood to ventilate the engine compartment When the water temperature drops stop the engine Check the cooling water level If it is low add more water Wear safety glasses and a face shield when usin...

Page 230: ... morning When the electrolyte level is low add distilled water in the morning before work instead of after the day s work This is to prevent fluid from freezing at night CARE AFTER DAILY OPERATION Drain water from the fuel system to prevent freezing Fill the tank at the end of each day of operation to drive out moisture laden air to prevent condensation Do not fill the tank to top Explosive fumes ...

Page 231: ...ompatible with AdBlue Description Specification Engine oil SAE 10W 30 15W 40 API CJ 4 class or better DEF AdBlue ISO 22241 32 5 high purity urea and 67 5 deionized water Transmission oil Engine oil SAE10W 30 API CF4 class or better Drive axle gear oil SAE 80W 90 Brake cooling oil Donax TD Hydraulic oil ISO VG46 VG68 Hyundai genuine long life hydraulic oil ISO VG15 Conventional hydraulic oil侏1 Grea...

Page 232: ...W SAE 10W 30 SAE 10W 30 SAE 80W 90 API GL 5 DONAX TD SAE 15W 40 SAE 15W 40 侏ISO VG 15 ISO VG 46 ISO VG 68 侏ASTM D975 NO 1 ASTM D975 NO 2 侏NLGI NO 1 NLGI NO 2 Ethylene glycol base permanent type 50 30 20 10 0 10 20 30 40 58 22 4 14 32 50 68 86 104 侏1 Ultra low sulfur diesel sulfur content 15 ppm 侏 Cold region Russia CIS Mongolia 侏Ethyleneglycolbasepermanenttype 60 40 侏SAE 5W 40 SAE numbers given to...

Page 233: ...t Tilt angle forward backward C C degree 15 12 ą ą Max height D mm ft in 4465 14 8 ą 4710 15 5 Min height E mm ft in 3000 9 10 ą 3250 10 0 Body Travel speed Unload km h 39 5 ą 33 3 Gradeability Load 45 3 41 0 40 2 Min turning radius Outside F mm ft in 4350 14 3 ą 4895 16 1 ETC Max hydraulic pressure kgf cm2 210 ą ą Hydraulic oil tank USgal 115 30 4 ą 124 3 32 8 Fuel tank USgal 195 51 5 ą 260 68 7 ...

Page 234: ... Compression ratio 17 3 1 Rated gross horse power ps rpm 165 8 2300 Maximum gross torque at rpm kgfÂm rpm 74 7 1500 Engine oil quantity U S gal 14 2 3 8 Dry weight kg lb 520 1146 High idling speed rpm 2250Ü50 Low idling speed rpm 600 1200 Rated fuel consumption g ps hr 168 Starting motor V kW DENSO 24 3 7 Alternator V A 24 70 Battery V AH 24 100 Item Unit Specification Type Variable displacement a...

Page 235: ...7 2 2 404 3 0 997 Axle Type Front wheel drive type fixed location Gear ratio 11 73 1 Gear Ring Pinion gear type Wheels Q ty FR RR Double 4 2 Front drive 10 00 20 16 PR Rear steer 10 00 20 16 PR Brakes Travel Front wheel wet disc brake Parking Axle pinion Caliper brake hydraulic released Steering Type Full hydraulic power steering Steering angle 76 to both right and left angle respectively Item Uni...

Page 236: ... 3 1 Rated gross horse power ps rpm 165 8 2300 Maximum gross torque at rpm kgfÂm rpm 74 7 1500 Engine oil quantity U S gal 14 2 3 8 Dry weight kg lb 520 1146 High idling speed rpm 2250Ü50 Low idling speed rpm 600 1200 Rated fuel consumption g ps hr 168 Starting motor V kW DENSO 24 3 7 Alternator V A 24 70 Battery V AH 24 100 Item Unit Specification Type Variable displacement axial piston pump Capa...

Page 237: ...47 2 2 404 3 0 997 Axle Type Front wheel drive type fixed location Gear ratio 12 7 1 Gear Ring pinion gear type Wheels Q ty FR RR Double 4 2 Front drive 12 00 20 18PR Rear steer 12 00 20 18PR Brakes Travel Front wheel Wet disk brake Parking Axle pinion caliper brake hydraulic released Steering Type Full hydraulic power steering Steering angle 76 to both right and left angle respectively Item Unit ...

Page 238: ...wer train system Transmission mounting bolt nut M16Ý2 0 100Ü15 723Ü109 8 Torque converter mounting socket bolt M10Ý1 5 4 5Ü0 6 32 5Ü4 3 9 Drive axle mounting bolt nut M24Ý2 0 100Ü15 723Ü109 10 Steering axle mounting bolt nut M24Ý3 0 100Ü15 723Ü109 11 Front Rear wheel mounting nut M22Ý1 5 83 2Ü10 602Ü72 3 12 Propeller shaft To D Axle T M 1 2 20UNF 15 0Ü2 0 108Ü14 5 13 Others Counterweight mounting ...

Page 239: ...ck of fuel ÂAir mixed in fuel system ÂFuel injection pump or nozzle defec tive ÂStarting motor rotates slowly ÂEngine compression insufficient ÂValve clearance out of adjustment ÂRefill fuel ÂBleed air ÂReplace ÂSee Electrical system ÂContact dealer ÂAdjust clearance ÂThermostat faulty ÂWater temperature gauge faulty ÂReplace ÂReplace ÂRadiator fin clogged or fin damaged ÂThermostat or water temp ...

Page 240: ...light when enig ne is stopped with starting switch left in ON position ÂCaution lamp defective ÂCaution lamp switch defective ÂReplace ÂReplace ÂFaulty wiring ÂGlow plug damaged ÂCheck and repair ÂReplace ÂFaulty wiring ÂInsufficient battery voltage ÂCheck and repair ÂRecharge battery ÂInsufficient battery voltage ÂStarting motor defective ÂRecharge battery ÂReplace ÂInsufficient battery voltage Â...

Page 241: ...ctioning ÂAir sucked in ÂWater intruding into transmission case ÂBearing worn or seizing ÂGauge malfunctioning ÂClutch dragging ÂBearing worn or seized ÂCheck oil level Add or drain oil as necessary ÂAfter draining oil from oil tank and transmission check and replace interfering parts ÂCheck enigne stalling speed If necessary replace ÂCheck the inlet side joint or pipe If necessary retighten joint...

Page 242: ... oil Check joints and pipes If necessary retighten joint or repla ce packing Check and replace Check oil pressure If necessary rep lace pump Check spring tension If necessary replace Disassemble check and repair or re place Disassemble check measure and re place Check stalling speed Increased engine load will cause ex cessive drop of stalling speed Check oil temperature rise If any replace free wh...

Page 243: ...ects and replace Probable cause Remedy 5 Power is not transmitted 1 Torque converter 2 Transmission ÂClutch plate damaged ÂLow oil level ÂOil pump driving system faulty ÂShaft broken ÂLack of oil pressure ÂLow oil level ÂInching valve and link lever improper ly positioned ÂForward reverse spool and link lever improperly positioned ÂClutch fails to disengage 1 Clutch case piston ring defective 2 Ma...

Page 244: ...ck ÂDisassemble and check for wear of seal lips and mating sliding surfaces pump boss coupling etc Replace oil seal pump boss coupl ing etc ÂCheck and retighten or replace pack ing ÂCheck and repair or replace gasket ÂCheck and retighten or gasket ÂCheck and replace cracked part ÂForeign matter intruding into oil pass age to clutch ÂShaft spline worn ÂDisassemble check and repair or replace ÂDisas...

Page 245: ... ÂOil inlet pipe sucks air Valve ÂFaulty Unbalance oil pressure Piping ÂPipe from pump to power steering dented or clogged ÂInsufficient air bleeding ÂFlow control valve orifice clogged Piping ÂPipe from tank to pipe dented or clogged ÂRetighten ÂReplace ÂAdjust ÂBleed air ÂAdjust valve set pressure and check for specified oil pressure ÂRepair or replace ÂAdd oil ÂRepair ÂBleed air completely ÂRep...

Page 246: ...ut of adjustment ÂHydraulic system clogged ÂAdjust tire pressure ÂAdjust ÂRepair by polishing or replace ÂAdjust or replace ÂClean ÂRepair and add oil ÂBleed air ÂReplace ÂRepair or replace ÂClean Probable cause Remedy 3 Brake trailing 4 Overheat ÂPedal has no play ÂPiston cup faulty ÂBrake valve return port clogged ÂHydraulic system clogged ÂWheel bearing out of adjustment ÂCooling oil insufficie...

Page 247: ...joint or hose ÂExcessive restriction of oil flow on pump suction side ÂRelief valve fails to keep specified pressure ÂPoor sealing inside cylinder ÂHigh hydraulic oil viscosity ÂMast fails to move smoothly ÂOil leaks from lift control valve spool ÂOil leaks from tilt control valve spool ÂExcessive restriction of oil flow pump suction side ÂGear or bearing in hydraulic pump defective ÂForeign matte...

Page 248: ...rmed masts or carriage ÂFaulty hydraulic equipment ÂDamaged load and side rollers ÂUnequal chain tension between LH RH sides ÂLH RH mast inclination angles are unequal Mast assembly is twisted when tilted ÂDisassembly repair or replace ÂSee Troubleshooting Hydraulic Cylinders pump and control valve in section 6 hydraulic system ÂReplace ÂAdjust chains ÂAdjust tilt cylinder rods Abnormal noise is p...

Page 249: ...verloading glancing blows against walls and objects and picking up load unevenly ÂDifference in fork tip height If the measured value exceeds the allowance replace fork Fatigue Fatigue failure may result from the fatigue crack even though the stress to fork is below the static strength of the fork Therefore a daily inspection should be done ÂCrack on the fork heel ÂCrack on the fork weldments Repa...

Page 250: ...k that accelerator pedal does not catch when depressed Check that engine speed increases in accordance with amount pedal is depressed When doing this check that engine speed changes without gasping abnormal noise abnormal explosions or irregular vibration Check that exhaust gas is colorless when the engine is idling and a thin black color when accelerator pedal is depressed Max speed SEE SECTION 8...

Page 251: ...D LUBRICATION Always use HYUNDAI Forklift genuine parts when replacing the element After replacing the element run the engine and check for oil leakage from the filter mount 1 2 3 5 ENGINE OIL Check oil level with dipstick and add oil if necessary Check oil for discoloration or deterioration Change oil if discolored or deteriorated Engine oil quantity 14 2再 3 8 U S gal 1 2 3 6 ENGINE OIL FILTER Th...

Page 252: ...oot of pulley center distance the belt tension must be adjusted Inspect the fan belt for damage Transverse across the belt cracks are acceptable Longitudinal direction of belt ribs cracks that intersect with transverse cracks are not acceptable Inspect the belt Embedded debris Uneven excessive rib wear Exposed belt cords Glazing high heat If any of the above conditions are present the belt is unac...

Page 253: ...erse solenoid valve operates and oil comes to reverse clutch thus the truck will run backward OIL LEAKAGE Check that there is no oil leakage from torque converter transmission or control valve If oil oozes out and forms drops replace packing 1 2 Η Θ 1 2 ADJUSTMENT OF PEDAL Accelerator pedal Pedal operating range is A If the range is differ much from specification replace the pedal immediately ÂOpe...

Page 254: ...so that pedal angle is H voltage 1Ü0 1V Pedal angle H 35Á ÂWhen fully pedaled voltage is controlled to 3 5Ü0 1V ÂAdjust bolt 3 so that brake pedal interconnects with inching pedal at inching pedal stroke 22 mm 0 9 in 3 1 2 3 22m m H 160D7ETA05 ...

Page 255: ...SPECIFICATIONS 2 RIM SIDE RING Check rim side ring for deformation or cracks Check visually or use crack detection method ÂRear rim connecting nut torque SEE SECTION 8 SPECIFICATIONS 3 D35ATA15 STEERING AXLE Push axle in from one side or measure front to rear clearance with feeler gauge Check that clearance is within 2mm If clearance is more than 2mm insert shim to reduce clearance to within 0 7 m...

Page 256: ...e 30 60 mm at rim of steering wheel If play is too large adjust at gearbox Test steering wheel play with engine at idling 30 60mm 1 2 2 4 in 1 2 STEERING AXLE Put camber gauge in contact with hub and measure camber If camber is not within 1Ü0 5 rear axle is bent Ask assistant to drive truck at minimum turning radius Fit bar and a piece of chalk at outside edge of counterweight to mark line of turn...

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Hyundai 110D-9, Manual

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