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10. Handling machine in extremely hot places - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-55

11. Cold weather operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-56

12. Storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-57

13. Transport - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-58

14. Loading and unloading by crane - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-59

15. Recommendation table for lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60

16. Fuel and lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-61

8. SPECIFICATIONS

1. Specification table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1

2. Specification for major components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-9

3. Tightening torque - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-29

9. TROUBLESHOOTING

1. Engine system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-1

2. Electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-2

3. Torque flow system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-3

4. Steering system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-7

5. Brake system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-8

6. Hydraulic system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9-10

10. TESTING AND ADJUSTING

1. Engine system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-1

2. Drive system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-5

3. Travel system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-9

4. Steering system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-10

5. Adjustment of parking brake lever - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-11

Summary of Contents for 15D-7E

Page 1: ...Vossendal 11 2440 Geel Belgium Authorized representative Owner of the technical file for machine production TCF Technical Construction File 3 Harmonized European directives ISO3691 1 3 ISO 20898 2008 EN ISO 2867 2008 4 Noise level Certain n Date Conformity assessment procedure Authorized entity Engine power Guaranteed sound power level e13 2000 14 2005 88 0059 08 2009 06 17 Attachment VIII followi...

Page 2: ... 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 op...

Page 3: ...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 to ...

Page 4: ...ect 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 truck o...

Page 5: ...rby 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 operate is n...

Page 6: ... 7 35DF 7 35D 40D 45D 7E 50D 7AE 35DS 40DS 45DS 50DA 7E 50D 60D 70D 7E 80D 7E 50DF 60DF 70DF 7 50DS 60DS 70DS 7E LPA 81 dB 80 dB 80 dB 82 dB 82 dB 82 dB 82 dB 82 dB LWA EU only 101 dB 103 dB 103 dB 106 dB 106 dB 107 dB 107 dB 107 dB Â The value of vibrations transmitted by the operator s seat are lower than standard value of 2002 44 EC 0 5 ...

Page 7: ... fan 8 Hydraulic oil 10 Start warning 11 Hand caution 12 Diesel fuel 13 Temperature 14 Parking brake 15 Warning safety 16 Hook 17 Safety instruction 18 Brake fluid 20 Model name 21 Noise 22 Load chart 23 Label UL 24 Name plate CE 25 Name plate UL 26 Fuse 27 Bonnet cover START SWITCH 5 12 15 11 16 1 2 20 8 20 1 2 16 27 3 10 18 14 DASHBOARD COVER DASHBOARD SUB BONNET BONNET FAN SHROUD 17 6 24 25 13 ...

Page 8: ...DASHBOARD COVER FAN SHROUD 17 14 18 10 6 START SWITCH 5 16 11 1 2 15 12 20 24 25 8 LOAD CAPACITY CHART 16 2 1 16 3 3 26 27 20 4 3 23 20D7EOM101 2 0 7 1 Logo 2 Warning plate 3 Tire caution 4 Air intake 5 Start key 6 Radiator fan 8 Hydraulic oil 10 Start warning 11 Hand caution 12 Diesel fuel 13 Temperature 14 Parking brake 15 Warning safety 16 Hook 17 Safety instruction 18 Brake fluid 20 Model name...

Page 9: ...H 15 21 4 23 35DFOM101 3 1 Logo 2 Warning plate 3 Tire caution 4 Air intake 5 Start key 6 Radiator fan 8 Hydraulic oil 10 Start warning 11 Hand caution 12 Diesel fuel 13 Temperature 14 Parking brake 15 Warning safety 16 Hook 17 Safety instruction 18 Brake fluid 20 Model name 21 Noise 22 Load chart 23 Label UL 24 Name plate CE 25 Name plate UL 26 Fuse box 27 Bonnet cover 0 8 ...

Page 10: ... 26 21 24 23 17 3 3 35D7EOM101 4 0 9 1 Logo 2 Warning plate 3 Tire caution 5 Start key 6 Radiator fan 8 Hydraulic oil 10 Start warning 11 Hand caution 12 Diesel fuel 13 Temperature 14 Parking brake 15 Warning safety 16 Hook 17 Safety instruction 18 Brake fluid 20 Model name 21 Noise 22 Load chart 23 Label UL 24 Name plate CE 25 Name plate UL 26 Fuse 28 Engine room 29 Hanger ...

Page 11: ...101 5 0 10 1 Logo 2 Warning plate 3 Tire caution 5 Start key 6 Radiator cap fan 8 Hydraulic oil 10 Start warning 11 Hand caution 12 Fuel 13 Temperature 14 Parking brake 15 Warning safety 16 Hook 17 Safety instruction 19 No step 20 Model name 21 Noise 22 Load chart 23 Label UL 24 Name plate CE 25 Name plate UL 26 Fuse 28 Engine room 30 Cab tilting warning 31 Accumulator 32 Safety work ...

Page 12: ...0DS7EOM101 6 1 Logo 2 Warning plate 3 Tire caution 5 Start key 6 Radiator fan 8 Hydraulic oil 10 Start warning 11 Hand caution 12 Diesel 13 Temperature 14 Parking brake 15 Warning safety 16 Hook 17 Safety instruction 18 Brake fluid 20 Model name 21 Noise 22 Load chart 23 Label UL 24 Name plate CE 25 Name plate UL 26 Fuse 29 Hanger 31 Accumulator 0 11 ...

Page 13: ...DF7OM101 7 1 Logo 2 Warning plate 3 Tire caution 5 Start key 6 Radiator cap fan 8 Hydraulic oil 10 Start warning 11 Hand caution 12 Fuel 13 Temperature 14 Parking brake 15 Warning safety 16 Hook 17 Safety instruction 18 Brake fluid wet 19 Hanger 20 Model name 21 Grease 22 Load capacity 24 Name plate CE 26 Sound 31 Accumulator 32 Safety work 0 12 ...

Page 14: ... warning label is positioned on the both side of the mast Never stand or work under the raised forks even if the hydraulic safety lock lever is applied In case of working under the forks it is essential to support the carriage with blocks 1 TEMPERATURE item 13 This warning label is positioned on the left of top side of sub bonnet Coolant must be checked as specified in the maintenance chart 2 0 13...

Page 15: ... open the filler cap while engine running or at high coolant temperature 3 25L7A0OM07 HAND CAUTION item 11 This label is positioned on respectively near the front fender and the rear fender of the left side of the main frame It warns of the danger of injury from movement between rails chains sheaves fork carriage and other parts of the mast assembly Do not climb on or reach into the mast Personal ...

Page 16: ...ning label is positioned on the dashboard cover if the truck is for USA or equipped with OPSS This forklift is equipped with an operator existence sensing system per ANSI ASME B56 1 7 21 10 7 21 11 and ASME ISO 3691 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...

Page 17: ...seconds from ON position It needs approx 5 6 seconds to set correct position of throttle Warnings before leaving the operator seat Be sure to lower the attachment to the ground Apply the parking brake Cautions before starting or operating the truck Put the gear shift lever in the neutral Apply the brake Read this operator s manual carefully 10 ö 1 2 0 16 92AD 00920 P 5 6 I 50DEFW55 25L7A0OM04 BRAK...

Page 18: ...ifted or being lifted Do not jump down from the machine It can be caused that the operator have severe injury or death in the event of a tip over Outstretch the legs as widely as possible and grasp firmly the steering handle Learn the body to the opposite direction in order to avoid severe injury or death when the machine is tipped over Refer to page 3 8 for details 12 Η Θ Ι Κ Λ Μ Ν ö N NOISE item...

Page 19: ... Rear D255SM01 2 SERIAL NUMBER Inform following when you order parts or the machine is out of order MACHINE SERIAL NUMBER It s shown on front of the right side frame 1 D255SM02 Important safety hint It indicates matters which can cause the great loss on the machine or the surroundings It indicates the useful information for operator 3 SYMBOLS ö 0 18 ...

Page 20: ...r 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 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 Fast turns and high loads 2 3 6 Drop offs 2 4 7 Right ...

Page 21: ...om a safe condition 5 9 6 General starting and operating tips 5 10 7 Starting the engine 5 11 8 Check after starting engine 5 12 9 Levers and pedals 5 14 10 Operating safely 5 16 11 Load handling 5 18 12 Shut down procedure 5 24 6 EMERGENCY STARTING AND TOWING 1 How to tow a disabled truck 6 1 2 How to use battery jumper cables 6 3 7 PLANNED MAINTENANCE AND LUBRICATION 1 Introduction 7 1 2 Safe ma...

Page 22: ...s 7 61 8 SPECIFICATIONS 1 Specification table 8 1 2 Specification for major components 8 9 3 Tightening torque 8 29 9 TROUBLESHOOTING 1 Engine system 9 1 2 Electrical system 9 2 3 Torque flow system 9 3 4 Steering system 9 7 5 Brake system 9 8 6 Hydraulic system 9 10 10 TESTING AND ADJUSTING 1 Engine system 10 1 2 Drive system 10 5 3 Travel system 10 9 4 Steering system 10 10 5 Adjustment of parki...

Page 23: ...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 1 SAFETY HINTS 1 DAILY INSPECTION D35AOM01 ...

Page 24: ...DO S AND DON TS D35AOM03 Do wear safety equipment when required D35AOM05 Don t mix drugs or alcohol with your job Don t block safety or emergency equipment D35AOM04 D35AOM02 Don t smoke in NO SMOKING areas or when refueling D35AOM06 ...

Page 25: ...he truck outdoors in rainy day öE Exclude the truck equipped cabin D35AOM07 Exhaust gas is dangerous Do not operate the truck at the inhouse if possible Provide adequate ventilation when working in a closed space D35AOM08 ...

Page 26: ...1 4 3 SEAT BELTS Seat belts can reduce injuries B207OM10 Always buckle up for the machine equipped with safety belt D507OM09 ...

Page 27: ...1 5 D255OM11A D255OM12A 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 28: ... same roadway you do Sound your horn at all intersections or blind spots D35AOM13 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 D35AOM15 5 PEDESTRIANS 1 2 3 ...

Page 29: ... 6 OPERATOR PROTECTION D35AOM16 Keep under the overhead guard Always keep your body within the confines of the truck Do not operate truck without overhead guard unless condition prevent use of a guard 1 2 ...

Page 30: ...aised forks D255OM17A There is special equipment to raise people for overhead work DO NOT USE LIFT TRUCKS D255OM12A Always lower the load slowly Raise and lower with mast vertical or tilted slightly back Never forward D255OM01 7 FORK SAFETY ...

Page 31: ... hands feet and legs out of the mast D255OM61 Don t use the mast as a ladder D255OM62 Never try to repair the mast carriage chain or attachment by yourself Always get a trained mechanic D255OM63 8 PINCH POINTS ...

Page 32: ... 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 D255OM24A 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 D255OM25A 9 TRAVEL 1 2 3 ...

Page 33: ...1 11 10 GRADES RAMPS SLOPES AND INCLINES D255OM26A D255OM27A Unloaded Forks downgrade Loaded Forks upgrade 1 2 Never turn on a grade either loaded or unloaded ...

Page 34: ...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 35: ...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 36: ...LWAYS BUCKLE UP D35AOM31 B207OM10 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 ...

Page 37: ...lete stop before leaving truck Be sure travel control is in NEUTRAL D35AOM34 Lower forks fully to floor and tilt forward OFF ON S T A R T 2 1 D255OM35A Set parking brake Position 1 Lock Position 2 Release Turn key to OFF position 13 PARKING 1 2 3 4 5 20D7OM24 ...

Page 38: ...e adding oil check around machine for oil leakage D255OM02 Keep away from fire when adding oil or during operation DIESEL D255OM03 After adding oil wipe off any oil spilled on machine D255OM04 14 REFUELING 1 2 3 ...

Page 39: ...1 17 When getting on or off the machine use the step provided D255OM05 Do not jump up or down from the machine D255OM06 15 STEP 1 2 ...

Page 40: ...ctional control 1 18 All operational functions require that the operator be seated in the operator s seat Always buckle up if a seat belt is provided D35AOM23 Parking brake must be locked in the PARK POSITION before exiting from the vehicle Parking brake must remain locked in the park position 2 except when an operator is in the normal operating position HYUNDAI 2 Lock Park 1 Release Drive D507OM2...

Page 41: ...e precautions Never carry loose or uneven material 2 OPERATING HAZARDS 1 LOOSE LOADS D255OM39 Center wide loads D35AOM40 Stack and band loose material D35AOM41 Avoid sudden braking or starting When the machine is loaded do not drive at maximum speed D255OM07 ...

Page 42: ...e 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 2 LONG AND WIDE LOADS D35AOM42 When turning be sure the rear end of the truck does not swing into racks posts etc Watch for pedestrians beside the truck 3 REAR SWING D255OM43 ...

Page 43: ...OM44 Watch overhead clearance Moving into overhead structures can tip a truck over or spill a load B207OM45 Slow down before turning The truck can tip over D255OM46 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 D255OM07 5 FAST TURNS AND HIGH LOADS ...

Page 44: ...trailer brakes Use wheel chocks Use trailer to dock locking system if available The impact of moving in and out of a trailer may cause the trailer to creep or move D35AOM48 D35AOM49 6 DROP OFFS When right angle stacking or moving with a raised load to clear low objects avoid sharp turns and move slowly 7 RIGHT ANGLE STACKING D35AOM50 1 2 3 4 ...

Page 45: ...ast lift the mast again and prevent chains from being slack 8 CHAIN SLACK D35AOM51 D35AOM52 Do not move or store materials on damaged pallets or skids Items can fall through them causing severe injury or death Be sure the pallet or skid you are using is in good condition and does not have defective or missing components and fasteners 9 PALLETS AND SKIDS D35AOM53 ...

Page 46: ...ECTRICAL LINES D255SF01 D255SF02 If the machine touches the electric power lines keep sitting on the operator s seat and make sure the personnel on the ground not to touch the machine until turning off the electric current Jump off the machine without contacting the machine when you need to get off Supply voltage 6 6 kV 33 0 kV 66 0 kV 154 0 kV 275 0 kV Min safe separation 3m 10ft 4m 13ft 5m 16ft ...

Page 47: ...t while the forks are not equipped with supports such as a load table for the load Never travel the fork lift while the side shift is moved with load In case of moving the side shift with load it can be caused load dropping or overturning of the fork lift due to unbalanced weight The fork lift can be overturned due to the unbalanced load 35D7EOM61 12 SIDE SHIFT ...

Page 48: ...ve the load to push or pull of it by the side shift It can be caused damaging of the loads or injuring of the people 35D7EOM62 While traveling the fork lift with the load on the side shift if the operator lift or lower the load without shifting it in the netural position it can be overturned the fork lift due to unstabled load When lifting or lowering the side shift with load it should be observed...

Page 49: ... operate the fork positioner with a load or with the fork arm on the ground Never move the levers to operate the pork positioner suddenly and quickly It can be caused to drop the load 35D7EOM65 13 FORK POSITIONER ...

Page 50: ...linder 4 Backrest 5 Tilt cylinder 6 Lift bracket 7 Forks 8 Overhead guard 9 Turn signal lamp 10 Head lamp 11 Operator s seat 12 Bonnet 13 Counterweight 14 Rear wheel 15 Front wheel 16 Rear combination lamp 9 10 1 2 4 6 7 15 5 14 12 13 16 11 8 3 15D7EOM54 15D 18D 20DA 7E 1 ...

Page 51: ...6 Lift bracket 7 Forks 8 Overhead guard 9 Turn signal lamp 10 Head lamp 11 Operator s seat 12 Bonnet 13 Counterweight 14 Rear wheel 15 Front wheel 16 Rear combination lamp 1 2 3 4 5 6 7 15 9 16 8 11 10 13 12 14 20D7OM01 20D 25D 30D 33D 7E 20DF 25DF 30DF 33DF 7 35DF 7 2 ...

Page 52: ...6 Lift bracket 7 Forks 8 Overhead guard 9 Turn signal lamp 10 Head lamp 11 Operator s seat 12 Bonnet 13 Counterweight 14 Rear wheel 15 Front wheel 16 Rear combination lamp 4 6 7 1 2 3 15 5 14 12 13 16 11 8 10 9 35DS7EOM54 35D 40D 45D 7E 50D 7AE 35DS 40DS 45DS 50DA 7E 3 ...

Page 53: ...krest 5 Tilt cylinder 6 Forks 7 Overhead guard 8 Turn signal lamp 9 Head lamp 10 Operator s seat 11 Bonnet 12 Counterweight 13 Rear wheel 14 Front wheel 15 Rear combination lamp 4 6 1 2 3 14 5 9 13 11 12 7 10 8 15 50DEOM54 50D 60D 70D 7E 80D 7E 4 ...

Page 54: ...Tilt cylinder 6 Lift bracket 7 Forks 8 Overhead guard 9 Turn signal lamp 10 Head lamp 11 Operator s seat 12 Bonnet 13 Counterweight 14 Rear wheel 15 Front wheel 16 Rear combination lamp 4 6 7 1 2 3 15 5 14 12 13 16 11 8 10 9 50DS7EOM54 50DS 60DS 70DS 7E 5 ...

Page 55: ... Backrest 5 Tilt cylinder 6 Forks 7 Overhead guard 8 Turn signal lamp 9 Head lamp 10 Operator s seat 11 Bonnet 12 Counterweight 13 Rear wheel 14 Front wheel 15 Rear combination lamp 6 4 2 3 9 8 7 10 12 11 13 5 14 1 60DF7CM54 50DF 60DF 70DF 7 6 ...

Page 56: ...oad 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 plus the weight of the load must b...

Page 57: ...on the front right hand leg of the drivers overhead 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 enough to jump clear of the truck and over...

Page 58: ...harge warning lamp 7 T M oil temp warning lamp 8 Air cleaner element warning lamp 9 Head lamp signal lamp 10 Right turn signal lamp 11 Fuel gauge 12 Engine check lamp 13 Parking brake signal lamp 14 Hour meter 15 Preheater signal lamp 16 Water separator lamp 17 Work lamp switch opt 18 Hazard lamp switch opt 19 Seat belt warning lamp 20 Parking brake lever 21 Inching pedal 22 Brake pedal 23 Acceler...

Page 59: ...y charge warning lamp 7 T M oil temp warning lamp 8 Air cleaner element warning lamp 9 Head lamp signal lamp 10 Right turn signal lamp 11 Fuel gauge 12 Engine check lamp 13 Parking brake signal lamp 14 Hour meter 15 Preheater signal lamp 16 Water separator lamp 17 Work lamp switch opt 18 Hazard lamp switch opt 19 Seat belt warning lamp 20 Parking brake lever 21 Inching pedal 22 Brake pedal 23 Acce...

Page 60: ...t 19 Seat belt warning lamp 20 Parking brake lever 21 Inching pedal 22 Brake pedal 23 Lift lever 24 Tilt lever 25 Attach 1 lever opt 26 Attach 2 lever opt 27 Horn button 28 Head lamp switch 29 Illumination lamp 30 Turn signal switch 31 Steering wheel 32 Forward reverse lever 33 Steering column adjust lever 34 Operator safety lamp OPSS DETAIL A HYUNDAI H E F 0 0 0 0 0 0 C LPG 17 18 19 1 2 3 4 5 8 9...

Page 61: ...r opt 28 Attach 3 lever opt 29 Full automatic switch 30 Clutch cutoff switch 31 Work lamp switch 32 Beacon lamp switch opt 33 Inching pedal 34 Brake pedal 35 Accelerator pedal 36 Steering wheel 37 Steering wheel knob 38 Engine check lamp 39 Brake fail warning lamp 40 T M error warning lamp 41 Water separator lamp 42 Engine coolant temperature warning lamp 43 Seat belt warning lamp 44 OPSS lamp 45 ...

Page 62: ...ad lamp switch 23 Clearance lamp switch 24 Turn signal switch 25 Horn button 26 Lift lever 27 Tilt lever 28 Attach 1 lever opt 29 Attach 2 lever opt 30 Hazard lamp switch 31 Full automatic switch 32 Inching switch 33 Work lamp switch 34 Beacon lamp switch opt 35 Inching pedal 36 Brake pedal 37 Accelerator pedal 38 Steering wheel 39 Steering wheel knob 40 Steering column adjust lever 41 OPSS lamp H...

Page 63: ...switch opt 18 Hazard lamp switch opt 19 Beacon switch 20 Parking brake lever 21 Inching pedal 22 Brake pedal 23 Lift lever 24 Tilt lever 25 Attach 1 lever opt 26 Attach 2 lever opt 27 Horn button 28 Head lamp switch 29 Illumination lamp 30 Turn signal switch 31 Steering wheel 32 Forward reverse lever 33 Steering column adjust lever 35 Engine check lamp STD 36 Operator safety lamp OPT P 13 4 5 7 6 ...

Page 64: ...ound FUEL GAUGE 1 This indicates the time of total machine operation All service intervals for periodic maintenance are based on service meter readings The last digit advances by 1 10 hours 50D 60D 70D 7E 80D 7E Refer to page 3 19 HOUR METER 2 4 INDICATOR SYMBOLS 1 2 3 ö 1 ö 2 ö 000000 15D7EOM02K 60DFOM10K E F 15D7EOM10K E F 1 2 160D7ECD04 60DFOM02K ...

Page 65: ...e range 40 107Á C 104 225Á F ÂRed range 107Á C 225Á F above The white range indicates when operating Keep idling engine at low speed until the white range indicates before operation of machine If the indicator is in the red range it means the transmission is overheated Be careful that the indicator does not move into the red range T TRANSMISSION OIL TEMPERATURE GAUGE 1 2 4 C H Red 160D7ECD11 4 4 4...

Page 66: ... the starting switch is turned ON the lamp will lights up but it should go out after the engine starts If the lamp lights up during operation stop the engine and check the fan belt tension and the electrical system BATTERY CHARGE WARNING LAMP 1 ö ö 8 8 3 17 This lamp lights up when key is turned to ON position After a while the heater signal lamp goes out then turn the key to START position PRE HE...

Page 67: ... W WORKING LAMP SIGNAL LAMP 1 12 Η Θ D35AOM86 Right turn signal lamp flickers when pulling on the turn signal lever R RIGHT TURN SIGNAL LAMP 1 14 D35AOM88 This lamp shows that the parking brake is applied or not Parking brake locked Signal lamp lights up Parking brake unlocked Signal lamp goes out Make sure that the signal lamp goes out before operating the machine PARKING BRAKE SIGNAL LAMP 1 15 P...

Page 68: ...s 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 in the normal operating position to regain powered direction control OPERATOR SAFETY LAMP 35D 40D 45D 7E 50D 7AE 50D 60D 70D 7E 80D 7E OPSS equipped 1 2 3 18 D357OM905T This lamp lights ON during a nonfatal e...

Page 69: ...until any problems are corrected 1 2 ö BRAKE FAIL WARNING LAMP 20 This lamp is turned ON when the temperature of cooling water is over the normal temperature 104Á C 219Á F Check the cooling system when the lamp is ON 1 2 ENGINE OVERHEAT WARNING LAMP 21 77073CD16 77073CD17 FUEL LOW LEVEL WARNING LAMP 22 Fill the fuel immediately when the lamp is turned ON 1 77073CD23 ...

Page 70: ...2 160D7ECD24 This switches are used to choose the model Model select mode The model is displayed on the LCD when the menu button and next button are pressed simultaneously for some longer seconds Please don t change your truck model identity because it is already pre set on the truck before delivery Η Θ ö 160D7ECD23 B Buzzer stop button 1 Menu and next button 2 CLUSTER BUTTON 50D 60D 70D 7E 80D 7E...

Page 71: ...E 80D 7E 24 Display initialization state with HYUNDAI logo and program version Η 160D7ECD25 START MODE DISPLAY 1 Displays rpm Odometer Hourmeter Η Θ Ι 50DECD33 S STANDBY MODE DISPLAY 2 On model select mode displays like this image Refer to the page 3 21 Η ö 50DECD35 M MODEL SELECT DISPLAY 3 Η Θ Ι ...

Page 72: ...ror number Also sporadically occurring errors can be indicated 25 1 S T O P h f a e d b c Left side Central side Right side g 1 2 3 4 5 Bars Left side Central and Right side Spanner Letters STOP a f b c d e g h Automatic range up and down shifting Preselected gear For the moment still without function On the two alphanumeric 16 segment display the electric control unit issues the actual state of g...

Page 73: ...lector to neutral position and again to F to R position a f Cold start phase Transmission in neutral until parking brake is released Machine starts to move after release of parking brake ö Gear will engage when turbine speed drops Select neutral to get fault code displayed Changes between actual gear direction while driving in neutral only displayed if no fault is detected spanner Changes between ...

Page 74: ...3 hex 34 hex 35 hex 36 hex 37 hex 38 hex 39 hex Meaning of error code Logical error at gear range signal Logical error at direction select signal Short circuit to battery voltage at clutch cutoff input Short circuit to ground or open circuit at clutch cutoff input Short circuit to battery voltage or open circuit at temperature sensor input Short circuit to ground at temperature sensor input Short ...

Page 75: ...ery voltage at clutch KE Short circuit to ground at clutch KE Open circuit at clutch KE Short circuit to battery voltage at clutch KV Short circuit to ground at clutch KV Open circuit at clutch KV Short circuit to battery voltage at clutch KR Short circuit to ground at clutch KR Open circuit at clutch KR Short circuit to ground at relay reverse warning alarm Short circuit to battery voltage at rel...

Page 76: ...rt circuit to battery voltage at power supply for sensors Short circuit to ground at power supply for sensors Low voltage at battery High voltage at battery Error at valve power supply 1 Error at valve power supply 2 Communication failure on devicenet General EEPROM fault Configuration lost Application error ...

Page 77: ... Twist the handle just opposite until the notch being aligned to ù ù or ú When clearance lamp light up then the Clearance lamp and all panel lamps light up too CLEARANCE LAMP SWITCH 1 2 ö 2 2 1 5 4 5 ton 50DA 7E 5 0 8 0 ton Head lamp lights up Twist the handle beneath steering wheel and make the notch align to or Small lamp goes out Twist the handle just the opposite direction described as above H...

Page 78: ... in the middle position for the autoshift function changing from 1 1st to 3rd gear shift mode Automatic 2nd mode Ι Press the bottom of the switch fully for the autoshift function changing from 2nd to 3rd gear shift mode A A M A A M 1 2 FULL AUTOMATIC SWITCH 50D 60D 70D 7E 80D 7E 1 2 3 D507CD60 Η Θ Ι 7 7 CLUTCH CUT OFF SWITCH 50D 60D 70D 7E 80D 7E This switch is pressed it will cut off the clutch w...

Page 79: ...9 Horn By pressing position Η the horn sounds and by releasing the horn stops S 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 28 for the tilting method of the cabin 2 1 CABIN TILTING SWITCH 50D 60D 70D 7E 80D 7E 10 1 2 ö 50DECD74 This switch i...

Page 80: ...1 D35AOM98 Position 1 Parking brake is applied and front wheel is locked Position 2 Parking brake is released Before moving the truck be sure the parking brake is released PARKING BRAKE LEVER 1 2 ö 1 18 1 2 D35AOM96 The horn sounds when the button is depressed HORN BUTTON 1 15 1 5 4 5 ton 5 0 8 0 ton 1 5 4 5 ton 50DA 7E 15D7EOM97 RATCHET TYPE 1 5 3 3ton 35DF 7 50D 60D 70D 7E 50DF 60DF 70DF 7 80D 7...

Page 81: ...ver is released the lifting or lowering action stops Lifting speed is controlled by accelerator pedal Lowering speed is controlled by lever only LIFT LEVER 1 2 3 ö 1 19 Lift Lower D507OM17 LH MOVEMENT Push the lever forward to move the left hand for the side shift RH MOVEMENT Pull the lever backward to move the right hand for the side shift LH RH LEVER FOR SIDE SHIFT WIDTH FORK POSITIONER SIDE SHI...

Page 82: ...K POSITIONER 2 160D7CD19 LH MOVEMENT Push the lever forward to move the left hand for the side shift RH MOVEMENT Pull the lever backward to move the right hand for the side shift LH RH 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 LEVER FOR SIDE SHIFT WIDTH FORK POSITIONER SIDE SHIFT 23 FORK POSITIONER ...

Page 83: ... 24 Steering column cover RH side Release Lock 25L7OM91 Release Lock 60DFOM109 Â50DF 60DF 70DF 7 By pulling down the lever the wheel is adjustable to tilt By pulling up the lever the wheel is adjustable to telescope 1 2 160D7ECD70 Â50D 60D 70D 7E 80D 7E R RH FORK MOVEMENT Push the lever forward to move outward for the RH fork Pull the lever backward to move inward for the RH fork Outward Inward 16...

Page 84: ...0 8 0 ton 1 5 3 3 ton Engine hood Lock latch Pull Lock latch 50D7ECD25 1 1 5 3 3 ton 35DF 7 METHOD OF ADJUSTING STEERING WHEEL ANGLE Turn the lock knob down Move the steering wheel forward or backward to select the most suitable position Turn knob up to lock the steering wheel in the desired position After adjusting try to move the steering wheel backward and forward to check that it is locked in ...

Page 85: ... It is possible to control the fan speed to four steps Η OFF Θ Fan speed 1 Ι Fan speed 2 Κ Fan speed 3 Λ Fan speed 4 1 1 AIR CONDITIONER AND HEATER 1 Fan speed control switch Airconditioner select switch Air position control switch Inlet air control switch Temperature control switch Air conditioner heater switch Radio USB player Rear Front 50DFCD90 50DECD50 ...

Page 86: ... 2 50DECD51 There are three steps of air flow Front Front defrost Defrost Η Θ Ι This switch regulates the inlet air Position Η Fresh air intake Position Θ The air ciculates in the cab I Inlet control switch 4 50DECD52 This switch is used to operate or stop the air conditioner When operating the air conditioner the lamp is lighted up Air conditioner select switch Η Θ Lamp 50D7ECD54 5 Η Θ Â Â Blue R...

Page 87: ...ing button ÂVolume VOL button Volume VOL button 2 2 Turn the VOL button clockwise to increase the volume and counter clockwise to decrease the volume VOL SELECT PUSH Η 2209S3CD70B 2 1 4 5 3 LCD 6 2209S3CD70 RADIO AND USB PLAYER RADIO AND USB PLAYER ÿBASIC FUNCTIONS BASIC FUNCTIONS 2 2 1 Power PWR button 2 Volume Sound setting button 3 Mode selection button 4 Radio FM AM selection button 5 USB slot...

Page 88: ...djustments for 3 seconds the changes will be saved and the previous mode will be restored Left Right BALANCE adjustment Left Right BALANCE adjustment Turn the SELECT button clockwise to increase the right side speaker volume and counter clockwise to increase the left side speaker volume BALANCE can be adjusted from 10L 10R If there are no adjustments for 3 seconds the changes will be saved and the...

Page 89: ...y when corresponding devices are connected devices are connected When connecting iPod AUX and front USB cannot be When connecting iPod AUX and front USB cannot be connected connected The iPod is connected to the USB in the machine handfree The iPod is connected to the USB in the machine handfree MODE Η Θ Ι ö ö ö 3 3 2209S3CD70D Radio FM AM selection button Radio FM AM selection button USB USB slot...

Page 90: ...cond FM 87 7 107 9 MHz 200 KHz AM 530 1710 KHz 10 KHz Ķ Local Middle East Asia Frequency Press the FM AM and Preset 2 button simultaneously to set frequency in accordance to the Local Middle East Asia Frequency settings lnT will become displayed on the LCD for one second FM 87 5 108 MHz 100 KHz AM 531 1602 KHz 9 KHz Ķ Europe Frequency Press the FM AM and Preset 3 button simultaneously to set frequ...

Page 91: ...sed to search frequencies manually a press of the SEEK step refer to note below will change the frequency Pressing and holding the button will continue changing the frequency Releasing the button will stop the search at the current frequency FLDR Ě Searches frequencies higher than current frequency FLDR ě Searches frequencies lower than current frequency SEEK STEP FM 100KHz AM 9KHz SEEK STEP FM 10...

Page 92: ... will be displayed on the LCD DISPLAY However the beep will not sound if the beep function has been turned off in sound setting After saving is complete pressing the preset button will play the corresponding broadcast frequency No beep sound signifies that the preset has not been saved In No beep sound signifies that the preset has not been saved In this case try again from the first step However ...

Page 93: ... a USB to the audio will automatically convert to USB mode Connecting the USB when the starting switch is in ON state will turn the power on and automatically play the songs within the USB Â Â TRACK UP SEEK TRACK UP SEEK DOWN DOWN button button 2 2 While playing USB press the TRACKĚ button to play the beginning of the next song Press the SEEKě button to return to the beginning of the current song ...

Page 94: ...is complete the current song will properly play from the beginning even if you continue holding the button Shortly pressing the buttons will not operate the FF REW While music is playing shortly press the RPT button to repeat the currently playing song RPT function Press and hold the RTP button to sequentially repeat all songs within the current folder FOLDER RPT however music files in the USB mus...

Page 95: ...utton to select the folder Turn the SELECT button left right to find the desired song and press the SELECT button to play If there are no adjustments for 3 seconds after pressing the SELECT button the function will be turned off and the USB play screen will be displayed Displays the info of the currently playing song F USB Displays USB is connected to the Audio Front R USB Displays USB is connecte...

Page 96: ... Connecting the USB when the starting switch is in ON state will turn the power on and automatically play the songs within the iPod The iPod cable is supplied separately   TRACK UP SEEK DOWN button TRACK UP SEEK DOWN button 2 2 While playing music press the TRACKĚ button to play the beginning of the next song Press the SEEKě button to return to the beginning of the current song Press the button ...

Page 97: ... ARTIST Ą ALBUM Ą TITLE Displays the file name of the currently playing song on the LCD Here the SCR button turns the file name SCROLL ON OFF While an iPod is operating press and hold the FF button to fast forward the song When fast forward is complete the next song will properly play from the beginning even if you continue holding the button Press and hold the REW button to rewind the song When r...

Page 98: ...gory Category will be displayed in the following order PLAYLISTS Ą ARTISTS Ą ALBUMS Ą GENRES Ą SONGS Ą COMPOSERS Ą AUDIOBOOKS Ą PODCACSTS After finding the category press the SELECT button to select the category Turn the SELECT button left right to find the desired song and press the SELECT button to play If there are no adjustments for 3 seconds after pressing the SELECT button the function will ...

Page 99: ...verted and play music from AUX Connecting the AUX when the starting switch is in ON state will turn the power on and automatically play the songs within the AUX Η Θ 1 1 Operates only when an external device is connected to AUX Connecting an AUX device to the audio using the AUX cable will automatically convert to AUX mode When an external device is connected only the PWR FM AM MODE and VOL buttons...

Page 100: ...mode TEL MUTE displayed ON audio LCD Lamp OFF Audio mode Mode change button Mode change button 2 2 SEEK VOL MIC MODE MUTE 21093CD52A 21093CD52B SEEK CALL MODE MUTE Mode change button Call button Handsfree jack MIC Power Volume switch SEEK VOL MIC CALL MODE MUTE Seek button Mute button Mode button 21093CD52 REMOTE CONTROLLER REMOTE CONTROLLER 3 3 This button is used answer a call last number redial...

Page 101: ...te button Short press this button to mute or cancel the mute silence while broadcasting SEEK VOL MIC MODE MUTE 6 6 21093CD52F Mode button Mode button 7 7 Press the mode button to select the desired mode FM1 FM2 AM CD FM1 The LCD displayed each mode The LCD displayed each mode SEEK VOL MIC MODE MUTE 21093CD52G This MIC transfers user voice to receiver of the call when making a call by handsfree Han...

Page 102: ...ck 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 for...

Page 103: ...icator lights Service brakes inching pedal and parking brakes Hydraulic controls lift tilt and auxiliary If installed Accelerator Directional control 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 a m...

Page 104: ...e distance while refueling 1 5 3 3 ton 3 5 8 0 ton 80D7OM106 D35AOM106 D35AOM106 D35AOM106 DANGER DIESEL FLAMMABLE USE CLEAN PROPERLY MARKED FUEL CANS CLEAN UP SPILLS 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 1 5 3 3 ton 35DF 7 ...

Page 105: ...nts 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 a DRIVER S OVERHEAD GUARD unless conditions prevent its use Do not remove overhead guard unless specifically authorized Use special care...

Page 106: ...3 4 7 5 6 8 9 11 12 A thorough walk around check should be made BEFORE starting engine This is required for your personal safety and to realize maximum service life for your machine The numbers on the inspection chart show the order of inspection These numbers correspond to the check item numbers given on the following pages Hang a caution sign on the truck for example Do not start or Maintenance ...

Page 107: ... the condition always replace the rim Never try repairing welding or heating 1 2 1 2 3 1 3 CHECK BEFORE STARTING ENGINE Tire air pressure Unit Item Front tire Single 15D 18D 20DA 7E 3 5 4 5t 50D 7AE 50DA 7E 9 0 128 8 8 16 19 116 137 157 186 30 50 217 362 294 490 53 71 383 513 520 696 52 70 376 506 510 686 53 71 383 513 520 696 kgf cm2 psi bar kgfÂm lbfÂft N m 8 5 121 8 3 7 75 110 7 6 9 0 128 8 8 8...

Page 108: ... tank is completely empty first add water directly to the radiator Then add water to the sub tank Always 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 radiator cap Wait until the radiator is cool enough to be touched by hand before opening the radiator cap Loosen th...

Page 109: ... Â50D 60D 70D 7E 80D 7E 10 15mm 0 4 0 6in Â50DF 60DF 70DF 7 10 15mm 0 4 0 6in Â50DS 60DS 70DS 7E 10 12mm 0 4 0 5in 1 D35AOM113 Wash the terminal with hot water if it is contaminat ed and apply grease to the terminals after washing Battery gas can explode Keep sparks and flames away from batteries Always wear protective glasses when working with batteries Do not stain clothes or skin with electroly...

Page 110: ... limit Lower limit TF430 QF790 29 32 Liter V300 TF400 23 26 Liter F L F L Upper limit Lower limit Upper limit Lower limit TF430 TF700 29 32 Liter V300 TF400 23 26 Liter 15D 18D 20DA 7E 20D 25D 30D 33D 7E F L F L Upper limit Lower limit Upper limit Lower limit 20DF 25DF 30DF 33DF 7 TF430 QF790 29 32 Liter V300 TF400 23 26 Liter 35DF 7 D357OM902 1 2 H E 0 0 0000 15D7EOM40K 1 2 50DEOM40 50D 60D 70D 7...

Page 111: ...lay for 50D 60D 70D 7E and 80D 7E ö I It must not adjust the free play for 50D 60D 70D 7E and 80D 7E ö CHECK HORN AND LAMPS 11 Check horn button and lamp switch if operate normally or not 1 2 Horn button 1 2 Lamp switch If horn and lamp are malfunctioning contact your HYUNDAI forklift distributor 1 2 1 1 1 5 4 5 ton 50DA 7E 5 0 8 0 ton 2 2 50DF 60DF 70DF 7 50DF7OM13 If the operating force is below...

Page 112: ...ator s weight The suspension stroke is 20mm upward and downward respectively SEAT ADJUSTMENT 1 BUCKLING UP 2 Buckling up Be sure that you put on the seat belt Connect and adjust the seat belt strap to a snug comfortable position Always wear your seat belt when operating a lift truck Failure to wear seat belt will result in injury or death in an event of an accident 1 L255OM119 The seat adjustable ...

Page 113: ...ntrols function All controls are in neutral or other correct position The truck has received its daily inspection and ready and safe to operate       Put the direction control 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 Forks are down Parking brake is set D255OM31 Neutral Forward Reverse D155OM...

Page 114: ...speed to approximately half throttle for a short period or until the engine coolant reaches approximately 100Á 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 fuel...

Page 115: ... the OFF and then into the ON position DO NOT USE STARTING FLUID to help start an engine The fluid contains ether or other explosive substances that could cause serious injury Starting fluid is especially dangerous when used on engines with glow plugs Never use starting fluid with a glow plug equipped engine Turn the start switch to the START position to crank the engine Release the key the ON pos...

Page 116: ...uel to prevent dirt from entering the tank Always fill the tank at the end of the day s operation If air remains in the tank the moisture in the air will condense inside the tank and form water in the fuel The moisture in the fuel system can be caused a difficulty of the engine starting and may lead to a serious problem for the engine function ö D Do not smoke or allow any flame near the truck whe...

Page 117: ... over 30 60mm 1 2 2 4in check or repair it CHECK STEERING WHEEL PLAY 5 30 60mm 1 2 2 4 in D35AOM127 FUEL LEVEL WARNING LAMP ENGINE OIL PRESSURE WARNING LAMP T M OIL TEMPERATURE WARNING LAMP BATTERY CHARGE WARNING LAMP AIR CLEANER ELEMENT WARNING LAMP WATER SEPARATOR WARNING LAMP ENGINE WARNING LAMP 35D7EOM126 1 5 5 0 ton 1 FUEL LEVEL WARNING LAMP ENGINE OIL PRESSURE WARNING LAMP BATTERY CHARGE WAR...

Page 118: ...namic 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 stability do not travel with the load or carriage in a highly elevated position Travel with the lift...

Page 119: ...L 5 D35AOM131 160D7OM131 50D 60D 70D 7E 80D 7E D35AOM132 160D7OM132 50D 60D 70D 7E 80D 7E D35AOM133 160D7OM133 50D 60D 70D 7E 80D 7E 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 enga...

Page 120: ...le impact 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 c...

Page 121: ...s your responsibility Be completely familiar with all the safe driving and load handling techniques in this Operator s Manual Use common sense Drive carefully do not indulge in stunt driving or horseplay Observe traffic rules Watch for people and hazards Slow down be in full control of your lift truck at all times Follow the instructions in this manual to avoid damage to your truck or the possibil...

Page 122: ...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 control to e...

Page 123: ... pushing them away from you Secure the fork locking pins Make sure the load backrest LBR or fork retaining bolts are fasten securely in place 2 D35AOM134 LOAD ON FORKS Do not elevate the load with one forks Loading with one fork can cause the tip over and serious injury or death of operator This can cause the height difference between both fork tips due to overload 1 3 D507OM137 Do not elevate the...

Page 124: ...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 125: ...load 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 126: ... 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 ...

Page 127: ...then 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 min...

Page 128: ...2 3 1 2 3 4 Forks are down Parking brake is set D255OM31 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 starting switch to the OFF position and remove the key Block the wheels if the truck must be left on an incline or you have any doubt about the truck moving from a safe position If the...

Page 129: ...r or ground Secure the carriage 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 tow...

Page 130: ... death to personnel near it Park the disabled truck in authorized areas only Fully lower the forks to the floor put the directional control lever in the NEUTRAL position and turn the starting switch to the OFF position Engage the parking brake Remove the key and when necessary block the wheels to prevent the truck from rolling 9 ...

Page 131: ...me to check and do not smoke If low add distilled water to the correct level 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 re...

Page 132: ... on the Jumper vehicle and run the engine at a moderate speed for a minimum of five minutes Start the engine on the Stalled vehicle 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 cables Remove the jumper cables by reversing the installation sequence exactly Start by removing the...

Page 133: ...dic 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 truck usage Planned maintenance is the normal maintenance ne...

Page 134: ...er s specifications 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 coo...

Page 135: ... 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 an eleva...

Page 136: ...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 137: ...than operation in clean 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 ...

Page 138: ...mance of machine Use 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 the...

Page 139: ...mp at the same time if the hose clamp is cracked when checking and replacing hose ö ö Periodical replacement of safety parts 1 2 3 4 5 6 7 8 9 10 11 Fuel hose Hydraulic pump hose Power steering hose Packing seal and O ring steering cylinder Lift chain Lift cylinder hose Tilt cylinder hose Side shift cylinder hose Master cylinder and wheel cylinder caps dust seals Brake hose or tube Brake reservoir...

Page 140: ...smission 9 Torque converter 10 Engine 11 Steering cylinder 12 Hydraulic pump 13 Steering axle Rear 14 Rear wheel 15 Muffler 16 Counterweight 17 Radiator 18 Operator s seat 19 Overhead guard 20 Steering wheel 21 Air cleaner 1 2 3 5 6 7 8 9 10 11 12 13 14 15 16 17 4 18 19 20 21 15D7EOM21 MAJOR COMPONENT LOCATIONS 15D 18D 20DA 7E 1 1 ...

Page 141: ... converter 10 Engine 11 Steering cylinder 12 Hydraulic pump 13 Steering axle Rear 14 Rear wheel 15 Muffler 16 Counterweight 17 Radiator 18 Operator s seat 19 Overhead guard 20 Steering wheel 21 Air cleaner 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 20D7OM21 20D 25D 30D 33D 7E 20DF 25DF 30DF 33DF 7 35DF 7 2 ...

Page 142: ...ansmission 11 Torque converter 12 Engine 13 Exhaust pipe 14 Air cleaner 15 Steering axle 16 Steering cylinder 17 Rear wheel 18 Radiator 19 Muffler 20 Silencer 21 Overhead guard 22 Seat 23 Control lever 24 Steering wheel 25 Drive shaft 1 2 3 4 6 7 8 9 10 11 12 13 14 15 16 17 21 22 23 24 5 18 19 20 25 35DEOM21 35D 40D 45D 7E 50D 7AE 3 ...

Page 143: ...ump 10 Transmission 11 Torque converter 12 Engine 13 Exhaust pipe 14 Air cleaner 15 Steering axle 16 Steering cylinder 17 Rear wheel 18 Radiator 19 Muffler 20 Silencer 21 Overhead guard 22 Seat 23 Control lever 24 Steering wheel 1 2 3 4 6 7 8 9 10 11 12 13 14 15 16 17 21 22 23 24 5 18 19 20 D357OM21 35DS 40DS 45DS 50DA 7E 4 ...

Page 144: ...lic pump 10 Priority valve 11 Transmission 12 Torque converter 13 Engine 14 Exhaust pipe 15 Steering axle 16 Steering cylinder 17 Rear wheel 18 Radiator 19 Muffler 20 Silencer 21 Air cleaner 22 Overhead guard 23 Seat 24 Steering wheel 25 Control lever 26 Steering unit 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1 2 3 4 5 26 22 23 25 24 50DEOM21 ...

Page 145: ...lve 11 Transmission 12 Torque converter 13 Engine 14 Exhaust pipe 15 Steering axle 16 Steering cylinder 17 Rear wheel 18 Radiator 19 Muffler 20 Silencer 21 Air cleaner 22 Overhead guard 23 Seat 24 Steering wheel 25 Control lever 26 Steering unit 26 1 2 3 4 5 21 22 23 24 25 6 7 20 8 9 10 11 12 13 14 15 16 17 18 19 50DS7EOM21 50DS 60DS 70DS 7E 6 ...

Page 146: ... pump 10 Priority valve 11 Transmission 12 Torque converter 13 Engine 14 Exhaust pipe 15 Steering axle 16 Steering cylinder 17 Rear wheel 18 Radiator 19 Muffler 20 Silencer 21 Air cleaner 22 Overhead guard 23 Seat 24 Steering wheel 25 Control lever 26 Steering unit 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 1 2 3 4 5 26 22 23 25 24 60DF7OM21 ...

Page 147: ...t level Radiator reservoir tank ÂWater separator ÂHydraulic oil level air breather filter return filter ÂFan belt tension and damage ÂTilt pin and mast roller Function tests ÂHorn and lamp ÂGauges and instrument panel ÂWarning light ÂService brake and inching operation ÂParking brake operation ÂAccelerator and engine speed operation ÂDirectional and speed control operation ÂSteering wheel operatio...

Page 148: ... cylinder tube end ÂSteering cylinder rod end ÂSteering cylinder tube end ÂAttachment option cylinder rod end ÂAttachment option cylinder tube end ÂSteering axle wheel bearing ÂPedal pivot Service Remarks E EVERY 500 HOURS SERVICE 6 Check items 1 Air cleaner element change interval may be determined by using an air restriction indicator 2 Diesel fuel filter change interval may be determined by fue...

Page 149: ...ement ÂAir breather filter Tire air pressure Service Remarks 5 12 5 6 7 32 7 32 7 32 7 44 7 35 7 31 7 34 7 34 7 34 7 45 5 3 E EVERY 2000 HOURS SERVICE 8 Check items Replace Replace Replace ÂHyd suction strainer ÂRadiator coolant ÂHydraulic oil 1 Service Remarks 7 34 7 35 7 34 E EVERY 5000 HOURS SERVICE 9 Check items Replace ÂHydraulic oil 2 Service Remarks 7 34 1 Conventional hydraulic oil 2 Hyund...

Page 150: ...ot 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 ö ö ö ö ö ö 1 1 5 3 3ton 35DF 7 1 5 MAINTENANCE CHART ...

Page 151: ... roller Hydraulic air breather filter Differential gear oil Trunnion bolt Fuel filter Engine oil filter Air cleaner element Battery Engine oil Differential gear oil Brake oil Hydraulic return filter Transmission oil Transmission oil filter Radiator coolant Hydraulic oil 1 Hydraulic strainer Hydraulic oil 2 2 3 5 6 8 9 11 14 15 16 18 20 21 25 9 11 12 13 22 26 22 23 1 2 3 16 26 4 7 10 11 17 18 26 5 ...

Page 152: ...l Hydraulic return filter Transmission oil Transmission oil filter Radiator coolant Hydraulic strainer Hydraulic oil 1 Hydraulic oil 2 2 3 5 6 8 9 11 14 15 16 18 20 21 25 9 11 12 13 22 26 22 23 1 2 3 16 26 4 7 10 11 17 18 26 5 20 22 23 12 19 19 19 Check Add Check Add Check Add Check Adjust Check Add Check Check Check Adjust Check Add Check Clean Check Add Check Clean Check Replace Check Adjust Cle...

Page 153: ...en servicing 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 ö ö ö ö ö ö 3 3 5 8 0ton 2 ...

Page 154: ...ck Adjust Check Add Check Add Check Clean Check Adjust Check Add Check Replace Check Add Check Drain Check Add Check Add Check Adjust Check Replace Check Clean Check Add Check Add Check Add Replace Replace Replace Check Lubricate Check Lubricate Clean Check Add Check Replace Check Adjust Replace Replace Replace Replace Replace Check Add Replace Replace Check Replace Replace Replace Replace Check A...

Page 155: ...age Transmission oil level Differential gear oil WET Differential gear oil DRY Transmission oil Transmission oil filter Tilt pin Mast roller Lift chain Engine oil Engine oil filter Hyd oil air breather element Differential gear oil Fork condition and wear Trunnion bolt Engine oil Engine oil filter Air cleaner element Differential gear oil WET Fuel filter Battery electrolyte Brake oil Hydraulic ret...

Page 156: ...t Hydraulic pump drive Steering axle linkage Transmission oil level Differential gear oil WET Differential gear oil DRY Transmission oil Transmission oil filter Tilt pin Mast roller Lift chain Engine oil Engine oil filter Hyd oil air breather element Differential gear oil Fork condition and wear Trunnion bolt Air cleaner element Differential gear oil WET Fuel filter Battery electrolyte Brake oil H...

Page 157: ...rd and any safety devices are in place undamaged and attached securely Check the overhead guard 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 LBR rails carriage rollers lift chains and lift and tilt cylinders Look for obvious wear and maintenance problems and damaged or missing pa...

Page 158: ...the fork with the 100mm 4in surface against the blade Put a 600mm 24in carpenter s square on the top of the block and against the shank Check the fork 500mm 20in above the blade to make sure it is not bent more than 25mm mm 1in 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 cr...

Page 159: ...lug nuts 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 opera...

Page 160: ...tion Working method of tilting cabin Refer to page 3 30 for the cabin tilting switch and hand pump switch Tilting cabin After keeping clearance of the people except the operator along with sounding horn insert the key in the hand pump switch and turn it clockwise and then press continuously for the tilting switch to tilt the cabin to right side Returning cabin After keeping clearance of the people...

Page 161: ...r is ON or engine is running It can cause severe injury or death Do not operate the tilt control switch or any control parts while servicing under the tilted cabin It can cause severe injury or death ON OFF START X O X 160D7MI65 WARN DO NOT OPERATE 50D7EMI64 ...

Page 162: ...ng 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 5Á 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 that the cooling performance is not damaged...

Page 163: ... adding distilled water be careful not to get electrolyte on your skin or clothes If electrolyte gets on your skin or clothes wash it off with fresh water immediately If electrolyte gets in your eyes wash it out with fresh water and go to a doctor immediately Battery indicator Battery condition Indicator Except 2 0 3 3 ton 35DF 7 Normal Insufficient distilled water Insufficient charge Mark Color G...

Page 164: ...type Remove the cover by pulling off the clamps and loosen the wing nut to pull out the outer element During periodic service replace only the outer element Do not replace the inner element unless damaged 2 1 Η ö Inner element Outer element Clamp Cleaning Cleaning with compressed air Blow dry compressed air Max 30psi from inside along pleats Next blow air form outside along pleats then blow from i...

Page 165: ...ement ÂRemove the filter using a filter wrench ÂClean the filter by removing dust and oil from the filter base bottom ÂInstall the new filter after thinly coating the packing surface with engine oil A After replacing the engine oil filter element start the engine to check for oil leakage from the filter mounting surface Check the engine oil level using the dipstick When adding engine oil do not le...

Page 166: ... protection rated for 200kPa 30psi is required for air cleaning operation ÂBlow dry compressed air from the inside of strainer to outside and install when completely dry ÂDispose of used oil in locally approved manner Dipstick Filter Drain plug 50DF 60DF 70DF 7 60DF7OM19 50DF 60DF 70DF 7 DIFFERENTIAL CASE Differential oil Park the truck in a level place Set the mast vertical and raise the forks ap...

Page 167: ...Drain plug Oil dipstick 15D 18D 20DA 7E 35DF 7 20DF 25DF 30DF 33DF 7 35DF7OM28 Drain plug Oil dipstick 20D 25D 30D 33D 7E 20D7EOM31 Drain plug Cap 35D 40D 45D 7E 50D 7AE 35DS 40DS 45DS 50DA 7E 50D 60D 70D 7E 80D 7E 35D7EOM28 35D 40D 45D 7E 50D 7AE 50D 60D 70D 7E 80D 7E Drain plug Cap 50DS 60DS 70DS 7E 50D7EOM28 20D 25D 30D 33D 7E 50DS 60DS 70DS 7E 60DF 70DF 7 Drain plug 60DF7OM28 50DF 60DF 70DF 7 ...

Page 168: ... hose clamps are tight Be sure to keep air or steam nozzle at right angles to radiator Wear safety glasses and a face shield when using compressed air 7 1 Radiator Cleaning Close drain valves and add clean soft water city water etc through water filler Add radiator cleaner and run the engine at idling speed for 15 minutes Stop engine and drain water from drain valves Add clean water and run at idl...

Page 169: ... Μ Ν Ξ ö D255OM29 When jacking up the truck always check carefully that the jack does not come out of position When 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 TIRE REPLACEMENT Park the truck in a safe and level place suitable for changi...

Page 170: ...A 15A 5A 15A 5A 5A 10A 10A TURN LAMP HORN BRAKE LAMP FUSES REPLACEMENT 9 15D 18D 20DA 7E 1 No Capacity 5A 5A 15A 5A 5A 10A 10A 5A 5A 10A 15A 5A Tan Tan Blue Tan Tan Red Red Tan Tan Red Blue Tan Stop solenoid Alt IG Travel Illumination Head lamp Start relay OPSS unit Turn lamp Horn Brake lamp Pre heating Cluster Work Beacon lamp Cabin OPSS unit Color Related electrical component STOP SOL ALT IG PRE...

Page 171: ...A 10A 10A 15A 20A 10A 15A 15A 10A 10A 15A FUSE HOLDER OPTION B Η Θ Ι Κ Λ Μ Ν Ξ Ο Π Ρ 3 35D 40D 45D 7E 50D 7AE 3 No Η Θ Ι Κ Λ Μ Ν Ξ Ο Π Ρ Capacity 10A 15A 10A 15A 20A 10A 10A 20A 10A 20A 10A 5A Blue Red Blue Blue Yellow Red Red Yellow Red Yellow Red White F R solenoid Glow relay Illumination Head lamp ECU Cluster Cabin ECU B Turn Stop lamp Horn Option Alternator Fuel heater Work lamp Option Air con...

Page 172: ...A 10A 10A 20A 10A 10A 10A 10A FUSE HOLDER STOP LAMP Η Θ Ι Κ Λ Μ Ν Ξ Ο Π Ρ No Η Θ Ι Κ Λ Μ Ν Ξ Ο Π Ρ Capacity 5A 10A 10A 10A 10A 10A 10A 10A 20A 10A 5A 10A Orange Yellow Green White Blue Orange Red Yellow Red Purple Violet Tilt alarm Back up lamp Turn lamp Tail lamp Rear work lamp Head lamp Alternator Wiper motor Air con 12V out Accel Start relay Color Relatedelectricalcomponent TILT ALARM WIPER MOT...

Page 173: ...latedelectricalcomponent TAIL BACK LAMP WORK LAMP TILT ALT FUEL CUT AIR CON CABIN GLOW START RELAY FUSE HOLDER HEAD LAMP 10A SPARE 10A SPARE 10A SPARE 15A 10A 15A 10A 20A 15A 10A 10A 10A 10A 10A TCU B HORN OPT 10A Η Θ Ι Κ Λ Μ Ν Ξ Ο Π Ρ Η Θ Ι Κ Λ Μ Ν Ξ Ο Π Ρ TCU TURN STOP LAMP CLUST ER OPSS 5 50DF 60DF 70DF 7 7 No Capacity 20A 10A 10A 10A 20A 5A 10A 10A 15A 15A 5A 10A Yellow Red Red Red Yellow Tan ...

Page 174: ...TRAL ÂForks are fully lowered to the floor or ground ÂAll controls are in neutral or other correct position ÂYou are familiar with the safety procedures given in section 5 S Starting and operating procedures in this manual As you test the following components be sure they are properly mounted and working correctly Horn Press the horn button to check horn function If the horn or any other part does...

Page 175: ...eable wobble Auxiliary controls Option If your lift truck is equipped with an attachment test the control lever for correct function and briefly operate the attachment Service brakes and inching pedal With the direction control in NEUTRAL and the engine running push the service brake pedal fully down and hold The brakes should apply before the pedal reaches the floor plate If the pedal continues t...

Page 176: ... in the REVERSE travel position Release the service brake and push down on the accelerator pedal until the truck moves slowly in the reverse direction 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 Put the directional control in FORWARD Press the inching pedal fully down and hold Depress the accele...

Page 177: ...ine coolant level open the hood to the engine compartment Visually inspect the recovery bottle locate the MAX and MIN marks The MAX mark indicates maximum level at operating temperature The MIN mark indicates additional coolant needs to be added to the system 7 44 Engine air cleaner Check the engine air cleaner for damage and contamination excessive dirt build up and clogging Be sure that the air ...

Page 178: ...d diesel engines HYUNDAI recommends that you use motor oil that meets API service classification CD CC SG SF and API CH4 SAE 15W 40 for diesel engines gas engines use API SG SAE 10W 30 oil or better Hydraulic sump tank Check the hydraulic sump tank fluid level Correct fluid level is important for proper system operation Low fluid level can cause pump damage Over filling can cause loss of fluid or ...

Page 179: ...tings Inspect the steering cylinder piston rods seals and fasteners for damage leaks and looseness Lubricate the steering axle linkage rod ends and linkage pivot points Be sure to clean the grease fittings before lubricating and remove the excess grease from all points after lubricating Lubricate miscellaneous linkage as needed Mast and tilt cylinder lubrication Clean the fittings and lubricate th...

Page 180: ... performance are a result of poor maintenance Chains need periodic maintenance to give maximum service life Do not attempt to repair a worn chain Replace worn or damaged chains Do not piece chains together 15 16 AIR CLEANING Always maintain a lift truck in a clean condition Do not allow dirt dust lint or other contaminants to accumulate on the truck Keep the truck free from leaking oil and grease ...

Page 181: ...5OM15 1 ö L Lift chain inspection and measurement Inspect and lubricate the lift chains every PM 50 250 hours When operating in corrosive environments inspect the chains every 50 hours During the inspection check for the following conditions ÂRust and corrosion cracked plates raised or turned pins tight joints wear and worn pins or holes ÂWhen the pins or holes become worn the chain becomes longer...

Page 182: ...d ù Change oil or add oil Figures in squares indicate number of lubricating points All service intervals in the chart are based on daily 2 weeks 1 month 3 months 6 months and service meter readings Η Θ Ι Κ 1 15D 18D 20DA 7E 20D 25D 30D 33D 7E 20DF 25DF 30DF 33DF 7 35DF 7 1 Mark EO MO GO HO BF G Kind of lubricants Engine oil T M oil Gear oil Hydraulic oil Brake fluid Grease In moderate weather In f...

Page 183: ...S 45DS 50DA 7E 2 Mark EO MO GO HO BF G Kind of lubricants Engine oil T M oil Gear oil Hydraulic oil Brake fluid Grease In moderate weather In freezing weather below 20Á C API CH4 class or better ATF DEXRON III MOBILFLUID 424 ISO VG 32 ISO VG 68 AZOLA ZS10 Hydraulic oil SAE 10W NLGI No 2 NLGI No 1 NOTES Ā Check add oil when needed ù Change oil or add oil Figures in squares indicate number of lubric...

Page 184: ...Mark EO MO GO HO BF G Kind of lubricants Engine oil T M oil Gear oil Hydraulic oil Brake fluid Grease In moderate weather In freezing weather below 20Á C API CH4 class or better ATF DEXRON III SAE 80W 90 API GL 5 DRY MOBILFLUID 424 WET ISO VG 32 ISO VG 68 DOT3 DRY AZOLA ZS10 Hydraulic oil SAE 10W WET NLGI No 2 NLGI No 1 NOTES Ā Check add oil when needed ù Change oil or add oil Figures in squares i...

Page 185: ...ift chain coated with engine oil Tilt cylinder Fork stopper Mast support Pedal pin 15D7EOM172 15D 18D 20DA 7E 1 Steering axle Lift chain coated with engine oil Tilt cylinder Fork stopper Mast support Pedal pin 20D7OM32 20D 25D 30D 33D 7E 2 ...

Page 186: ...axle Tilt cylinder Fork stopper Mast support Pedal pin D357OM172 35D 40D 45D 7E 50D 7AE 35DS 40DS 45DS 50DA 7E 4 Steering axle Lift chain coated with engine oil Tilt cylinder Fork stopper Mast support Pedal pin 20D7OM32 20DF 25DF 30DF 33DF 7 35DF 7 3 ...

Page 187: ...rt Adjust bolt Fork stopper Tilt cylinder Lift chain coated with engine oil Pedal pin 50D7EOM172 Lift chain coated with engine oil Steering axle Tilt cylinder Fork stopper Adjust bolt Mast support Pedal pin 50DS7EOM173 50DS 60DS 70DS 7E 50DF 60DF 70DF 7 6 ...

Page 188: ... 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 W Wear safety glasses and a face shield when using compressed air Never touch the radiator cap while the engine is hot Steam may spurt out Wait until the water temperature drops It is extremely dangerous to try to check t...

Page 189: ...e 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 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 may be present during refueling ...

Page 190: ...ater Remove the rocker housing cover and lubricate the valves and rocker arms well Inspect the valve operation After the engine is started run it at idling speed until it is warmed up completely BEFORE STORAGE When you keep your forklift truck in storage for an extended period of time observe the following safeguard instruction Wash and tidy the truck and house it in a dry building When the truck ...

Page 191: ...nd the loading dock Ensure that the transporter cannot move by applying the brake and putting blocks under the wheels Place the transmission control in NEUTRAL Fix the loading ramps securely so that the centers of the transporter and machine are aligned The loading ramps should be of sufficient width length and thickness to permit safe loading or unloading After checking that the machine is aligne...

Page 192: ...y Keep area clear of personnel 14 LOADING AND UNLOADING BY CRANE 1 2 3 4 5 Do not install the wire to unsafe position such as forks carriage head guard counterweight lifting hole or towing pin etc It can cause serious injury or damage to driver and truck If there is any problem to lift a truck please contact your dealer Perform the lifting service with skilled service men Wire rope Fork X Carriage...

Page 193: ...il Gear oil Hydraulic oil Brake oil Grease Fuel Coolant ȵNLGI National Lubricating Grease Institute ȵASTM American Society of Testing and Material SAE 10W 30 API CH4 class or better ATF DEXRON III MOBILFLUID 424 ISO VG32 VG46 VG68 AZOLA ZS10 Hydraulic oil SAE 10W Lithium base grease NLGI No 2 ASTM D975 No 2 Mixture of 50 ethylene glycol base antifreeze and 50 water SAE 10W 30 API CH4 class or bett...

Page 194: ...S gal Service point Kind of fluid Ambient temperature Á C Á F Engine oil pan Torque converter transmission Axle Hydraulic tank Fuel tank Fitting Greasenipple Brake reservoir tank Radiator Engine oil Hydraulic oil Diesel fuel Brake oil Grease Antifreeze Water 50 50 13 2 3 49 9 5 2 5 20 4 15D 18D 20DA 7E 2 0 3 3ton 35DF 7 10 14 0 32 10 50 20 68 30 86 40 104 Transmission oil Gear oil 10 2 6 10 2 6 5 ...

Page 195: ...nge must be doubled Η Η Θ Ι Ι NOTES Capacity U S gal Service point Kind of fluid Ambient temperature Á C Á F Engine oil pan Torque converter transmission Axle Hydraulic tank Fuel tank Fitting Greasenipple Brake reservoir tank Radiator Engine oil Hydraulic oil Diesel fuel Hyd oil Grease Antifreeze Water 50 50 HMC 8 5 2 2 MHI 16 5 4 3 20 4 10 14 0 32 10 50 20 68 30 86 40 104 T M oil Gear oil 12 3 2 ...

Page 196: ...Θ Ι Ι NOTES Capacity U S gal Service point Kind of fluid Ambient temperature Á C Á F Engine oil pan Torque converter transmission Axle Hydraulic tank Fuel tank Fitting Greasenipple Brake reservoir tank Radiator Engine oil Hydraulic oil Diesel fuel Hyd oil Grease Antifreeze Water 50 50 20 4 10 14 0 32 10 50 20 68 30 86 40 104 T M oil Gear oil 18 4 8 12 5 3 3 105 27 7 150 39 6 17 4 5 SAE 30 SAE 10W ...

Page 197: ... NOTES Capacity U S gal Service point Kind of fluid Ambient temperature Á C Á F Engine oil pan Torque converter transmission Axle Hydraulic tank Fuel tank Fitting Greasenipple Brake reservoir tank Radiator Engine oil Hydraulic oil Diesel fuel Hyd oil Grease Antifreeze Water 50 50 20 4 10 14 0 32 10 50 20 68 30 86 40 104 T M oil Gear oil 13 3 4 12 5 3 3 100 26 4 150 39 6 17 4 5 SAE 30 SAE 10W ISO V...

Page 198: ...D 7E 18D 7E Lifting height Free lift Lifting speed Unload Load Lowering speed Unload Load LÝWÝT Tilt angle forward backward Max height Min height Travel speed Gradeability Min turning radius Outside 1500 500 2850 3300 145 650 620 450 500 900Ý100Ý35 6 10 4332 2155 19 3 17 9 1985 1750 ą 3020 ą ą 650 620 ą ą ą ą ą ą 16 6 2013 Fork Mast Body H W M F M B T L A D E R C C G I J K G H I J K M M ETC Operat...

Page 199: ...Unit 20D 7E 25D 7E 30D 7E Lifting height Free lift Lifting speed Unload Load Lowering speed Unload Load LÝWÝT Tilt angle forward backward Max height Min height Travel speed Gradeability Min turning radius Outside 2000 500 3604 3300 155 590 560 450 500 1050Ý100Ý45 6 10 4485 2175 18 8 23 3 2252 2500 ą 3894 ą ą 590 540 ą ą ą ą ą ą 20 4 2300 3000 ą 4411 ą ą 500 480 ą 1050Ý125Ý45 ą ą 2190 19 7 16 6 239...

Page 200: ...lift Lifting speed Unload Load Lowering speed Unload Load LÝWÝT Tilt angle forward backward Max height Min height Travel speed Unload Gradeability Min turning radius Outside 2000 500 3430 3005 155 590 570 450 500 1050Ý100Ý45 6 10 4185 2025 17 6 18 8 2248 2500 ą 3720 ą ą 590 550 ą ą ą ą ą ą 16 4 2302 3000 ą 4237 ą ą 480 460 ą 1050Ý122Ý45 ą ą 2040 18 5 13 5 2398 Fork Mast Body G H I J K M M ETC Oper...

Page 201: ...pacity Load center Weight Unloaded Model Unit 35D 7E 40D 7E 45D 7E Lifting height Free lift Lifting speed Unload Load Lowering speed Unload Load LÝWÝT Tilt angle forward backward Max height Min height Travel speed Gradeability Min turning radius Outside 3500 600 5832 3020 120 570 550 500 500 1070Ý122Ý50 8 10 4224 2235 27 7 22 8 2840 4000 ą 6392 ą ą 570 540 ą 1070Ý150Ý50 ą ą 2220 26 7 22 4 2900 450...

Page 202: ... ą ą Capacity Load center Weight Unloaded Model Unit 35DS 7E 40DS 7E 45DS 7E Lifting height Free lift Lifting speed Unload Load Lowering speed Unload Load LÝWÝT Tilt angle forward backward Max height Min height Travel speed Gradeability Min turning radius Outside 3500 600 5894 3000 120 580 520 500 500 1070Ý122Ý50 8 10 4224 2235 27 1 21 2 2770 4000 ą 6464 ą ą ą ą 1070Ý150Ý50 ą ą 2220 26 1 19 2 2830...

Page 203: ...load Load LÝWÝT Tilt angle forward backward Max height Min height Travel speed Gradeability Min turning radius Outside 5000 600 8440 3030 140 460 440 450 500 1200Ý150Ý60 15 10 4275 2515 35 1 25 9 3270 7000 ą 9885 3030 ą 460 420 ą ą ą ą ą 34 8 20 4 3360 Fork Mast Body G H I J K M M ETC Operating pressure Hydraulic oil tank Fuel tank 188 105 160 ą ą ą kgf cm2 R 3570 ą ą 195 ą ą 60D 7E 6000 ą 9218 30...

Page 204: ...ift Lifting speed Unload Load Lowering speed Unload Load LÝWÝT Tilt angle forward backward Max height Min height Travel speed Gradeability Min turning radius Outside 5000 600 8602 3030 140 480 450 450 500 1200Ý150Ý60 15 10 4275 2500 35 5 24 8 46 2 3270 7000 ą 9871 ą ą 480 430 ą ą ą ą ą 35 2 20 0 36 5 3360 Fork Mast Body G H I J K M M ETC Operating pressure Hydraulic oil tank Fuel tank 185 105 150 ...

Page 205: ...Lifting speed Unload Load Lowering speed Unload Load LÝWÝT Tilt angle forward backward Max height Min height Travel speed Unload Gradeability Min turning radius Outside 5000 600 8382 3030 140 460 440 450 500 1200Ý150Ý60 15 10 4275 2515 22 8 24 6 45 8 3349 7000 ą 9871 ą ą 460 420 ą ą ą ą ą 22 8 21 1 38 5 3442 Fork Mast Body G H I J K M M ETC Operating pressure Hydraulic oil tank Fuel tank 185 100 1...

Page 206: ...gal kg lb rpm rpm g ps hr V kW V A V AH mm in Specification KUBOTA V2203 M E3B 4 cycle in line overhead valve Water cooling 4 cylinders in line 1 3 4 2 In direct injection 87Ý92 4 3 4 Ý3 6 2197 134 1 22 6 41 9 2400 14 3 1600 9 5 2 5 211 465 2600Ü50 850Ü50 180 DENSO12V 2 0kW DENSO 12V 40A 12V 75AH 7 9 0 28 0 35 M MAIN PUMP 2 Item Type Capacity Maximum operating pressure Rated speed Max Min cc rev b...

Page 207: ...t drive Rear steer FWD REV KAPEC 280 DK 3 Element 1 stage 2 phase 2 9 1 Full auto power shift 1 1 Electrical single lever type kick down system 2 137 2 214 Front wheel drive type fixed location 6 5 1 Ring pinion gear type 2 2 6 50 10 12 PR 5 00 8 10 PR Front wheel wet disk brake Ratchet band brake type Hydro static power steering 81äto both right and left angle respectively Travel Parking Type Ste...

Page 208: ...gfÂm rpm U S gal kg lb rpm rpm g ps hr V kW V A V AH mm in Specification KUBOTA V3600 Vertical water cooled 4 cycle diesel Water cooling 4 cylinders in line 1 3 4 2 Spherical type E TVCS 98Ý120 3 9Ý4 7 3620 221 22 6 65 4 2300 22 5 1700 13 2 3 5 272 600 2570 900Ü50 173 12V 3kW 12V 45A 12V 100AH 10 12 0 39 0 47 M MAIN PUMP 2 Item Type Capacity Maximum operating pressure Rated speed Max Min cc rev ba...

Page 209: ...APEC 280 DJ 3 Element 1 stage 2 phase 2 87 Power shift 1 1 Electrical single lever type kick down system 2 444 2 536 Front wheel drive type fixed location 6 5 Ring pinion gear type Single 2 2 Double 4 2 Single 7 0 12 12 PR Double 6 0 15 10 PR Single 28x9 15 14 PR Double 6 0 15 12 PR 6 00 9 10 PR 6 5 10 12 PR Front wheel wet disk brake Ratchet band brake type Full hydraulic power steering 78 9äto b...

Page 210: ... ps rpm kgfÂm rpm U S gal kg lb rpm rpm g ps hr V kW V A V AH mm in Specification HMC D4BB Vertical water cooled 4 cycle diesel Water cooling 4 cylinders in line 1 3 4 2 Swirl 91 1Ý100 3 6Ý3 9 2607 159 22 53 2500 17 2 1900 5 4 1 43 200 440 2570 750Ü100 173 12V 2 2kW 12V 65A 12V 130A 10 13 0 39 0 51 M MAIN PUMP 2 Item Type Capacity Maximum operating pressure Rated speed Max Min cc rev bar rpm Fixed...

Page 211: ... 2 5 3 0 3 3 KAPEC 280 DJ 3 Element 1 stage 2 phase 2 87 Power shift 1 1 Electrical single lever type kick down system 2 444 2 536 Front wheel drive type fixed location 6 5 Ring pinion gear type Single 2 2 Double 4 2 7 00 12 12 PR Single 8 5 15 14 PR Double 6 0 15 12PR 6 00 9 10 PR 6 5 10 12 PR Front wheel wet disk brake Ratchet band brake type Full hydraulic power steering 78 9äto both right and ...

Page 212: ... S gal kg lb rpm rpm g ps hr V kW V A V AH mm in Specification KUBOTA V3600 Vertical water cooled 4 cycle diesel Water cooling 4 cylinders in line 1 3 4 2 Spherical type E TVCS 98Ý120 3 9Ý4 7 3620 221 22 6 65 4 2300 22 5 1700 13 2 3 5 272 600 2570 870Ü25 173 12V 3kW 12V 45A 12V 100AH 10 12 0 39 0 47 M MAIN PUMP 2 Item Type Capacity Maximum operating pressure Rated speed Max Min cc rev bar rpm Fixe...

Page 213: ...r steer FWD REV KAPEC 280 DJ 3 Element 1 stage 2 phase 2 87 Power shift 1 1 Electrical single lever type 1 143 1 1 143 1 Front wheel drive type fixed location 14 2 1 Ring pinion gear type Single 2 2 Double 4 2 Single 8 5 15 14 PR Double 6 0 15 12PR 6 5 10 12 PR Front wheel wet disk brake Ratchet wet disk brake Full hydraulic power steering 78 9äto both right and left angle respectively Travel Park...

Page 214: ...ing order Combustion chamber type Cylinder bore X stroke Piston displacement Compression ratio Rated gross horse power Maximum torque at rpm Engine oil quantity Dry weight High idling speed Low idling speed Rated fuel consumption Starting motor Alternator Battery Fan belt deflection Unit mm in cc cu in hp rpm kgfÂm rpm U S gal kg lb rpm rpm g ps hr V kW V A V AH mm in Specification HYUNDAI D4DD 4 ...

Page 215: ... KAPEC 3 Element 1 stage 2 phase 2 25 1 Power shift 2 2 Electrical single lever type 1st 2 550 2nd 1 218 1st 2 550 2nd 1 218 Front wheel drive type fixed location 11 692 Single 2 2 Double 4 2 3 5 ton 8 25 15 14 PR 4 0 4 5 ton 300 15 18 PR 7 5 16 12 PR 3 5 4 5 ton 7 0 12 12 PR 5 ton 7 0 12 14 PR Front wheel wet disk brake Ratchet drum brake Full hydraulic power steering 74 8äto both right and left ...

Page 216: ... in ps rpm kgfÂm rpm U S gal kg lb rpm rpm g ps hr V kW V A V AH mm in Specification MITSUBISHI S6S T 4 cycle in line Vertical OHV Water cooling 6 cylinders in line 1 5 3 6 2 4 Indirect injection 94Ý120 3 7Ý4 7 4996 305 22 92 2300 29 9 1700 16 5 4 3 360 792 2570 820 180 24 5 0 24 50 12 96Ý2 10 12 0 4 0 5 M MAIN PUMP 2 Item Type Capacity Maximum operating pressure Rated speed Max Min cc rev bar rpm...

Page 217: ... 280 KAPEC 3 Element 1 stage 2 phase 2 25 1 Power shift 2 2 Electrical single lever type 1st 2 550 2nd 1 151 1st 2 550 2nd 1 151 Front wheel drive type fixed location 11 692 Single 2 2 Double 4 2 3 5 ton 8 25 15 14 PR 4 0 4 5 ton 300 15 18 PR 7 5 16 12 PR 7 0 12 12 PR Front wheel wet disk brake Toggle internal expanding mechanical type Full hydraulic power steering 74 8äto both right and left angl...

Page 218: ...rpm U S gal kg lb rpm rpm g ps hr V kW V A V AH mm in Specification HYUNDAI D4DD 4 cycle turbocharged diesel type Water cooling 4 cylinders In line 1 3 4 2 Direct injection 104Ý115 4 1Ý4 5 3907 238 17 5 1 100 2300 38 1600 8 5 2 2 350 772 2510Ü20 800Ü50 140 2 at 1700rpm 24 5 24 50 24 75 10 15 0 39 0 59 M MAIN PUMP 2 Item Type Capacity Maximum operating pressure Rated speed Max Min cc rev bar rpm Fi...

Page 219: ...steer FWD REV W280 2 526 248 3 Element 1 stage 2 phase 2 526 1 Full auto Power shift 3 3 Electrical single lever type 1st 4 446 2nd 2 341 3rd 0 974 1st 4 443 2nd 2 340 3rd 0 974 Front wheel drive type fixed location 10 545 Double 4 2 8 25 15 14 PR 8 25 15 14 PR Front wheel wet disk brake Ratchet drum brake Full hydraulic power steering 75 87äto both right and left angle respectively Travel Parking...

Page 220: ...rpm kgfÂm rpm U S gal kg lb rpm rpm g ps hr V kW V A V AH mm in Specification MITSUBISHI S6S T 4 cycle in line Vertical OHV Water cooling 6 cylinders in line 1 5 3 6 2 4 Indirect injection 94Ý120 3 7Ý4 7 4996 305 22 92 2300 29 9 1700 16 5 4 3 360 792 2570 820 180 24 5 0 24 50 12 96Ý2 10 12 0 4 0 5 M MAIN PUMP 2 Item Type Capacity Maximum operating pressure Rated speed Max Min cc rev bar rpm Fixed ...

Page 221: ... 526 248 3 Element 1 stage 2 phase 2 526 Full auto Power shift 3 3 Electrical single lever type 1st 4 446 2nd 2 341 3rd 0 974 1st 4 443 2nd 2 340 3rd 0 973 Front wheel drive type fixed location 10 545 Double 4 2 8 25 15 14 PR 8 25 15 14 PR Front wheel Duo servo dry wet disk brake wet Toggle internal expanding mechanical type Full hydraulic power steering 75 87äto both right and left angle respecti...

Page 222: ...m rpm U S gal kg lb rpm rpm g ps hr V kW V A V AH mm in Specification HYUNDAI D4DD 4 cycle turbocharged diesel type Water cooling 4 cylinders In line 1 3 4 2 Direct injection 104Ý115 4 1Ý4 5 3907 238 17 5 1 100 2300 38 1600 8 5 2 2 350 772 2510Ü20 800Ü50 140 2 at 1700rpm 24 5 24 50 24 75 10 15 0 39 0 59 M MAIN PUMP 2 Item Type Capacity Maximum operating pressure Rated speed Max Min cc rev bar rpm ...

Page 223: ...e Stall ratio Type Gear shift FWD REV Control 3 Element 1 stage 2 phase 2 526 Full auto Power shift 2 2 Electrical single lever type 1st 4 97 2nd 1 55 1st 4 97 2nd 1 55 Front wheel drive type fixed location 10 545 Double 4 2 8 25 15 14 PR 8 25 15 14 PR Front wheel Duo servo dry wet disk brake wet Toggle internal expanding mechanical type Full hydraulic power steering 75 87äto both right and left a...

Page 224: ...U S gal kg lb rpm rpm g ps hr V kW V A V AH mm in Specification HYUNDAI D4DD 4 cycle turbocharged diesel type Water cooling 4 cylinders In line 1 3 4 2 Direct injection 104Ý115 4 1Ý4 5 3907 238 17 5 1 100 2300 38 1600 8 5 2 2 350 772 2510Ü20 800Ü50 140 2 at 1700rpm 24 5 24 50 24 75 10 15 0 39 0 59 M MAIN PUMP 2 Item Type Capacity Maximum operating pressure Rated speed Max Min cc rev bar rpm Fixed ...

Page 225: ... steer FWD REV W280 2 526 248 3 Element 1 stage 2 phase 2 526 1 Full auto Power shift 3 3 Electrical single lever type 1st 4 446 2nd 2 341 3rd 0 974 1st 4 443 2nd 2 340 3rd 0 974 Front wheel drive type fixed location 12 4 Double 4 2 8 25 15 14 PR 8 25 15 14 PR Front wheel wet disk brake Ratchet drum brake Full hydraulic power steering 75 87äto both right and left angle respectively Travel Parking ...

Page 226: ...0 8 72Ü7 2 434Ü36 18 1Ü3 6 44 8 kgfÂm lbfÂft Hydraulic system Power train system 2 20D 25D 30D 33D 7E 2 No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Item Size Engine Others Engine mounting nut bracket frame Engine mounting bolt engine bracket Radiator mounting bolt nut Torque converter mounting bolt 8EA MCV mounting bolt Steering unit mounting bolt Transmission mounting bolt nut Drive axle mounting bolt nu...

Page 227: ...142Ü21 50Ü10 142Ü10 50Ü10 50Ü10 560Ü84 142Ü21 448Ü67 434Ü36 1555Ü239 18 1Ü3 6 93Ü22 kgfÂm lbfÂft Hydraulic system Power train system No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Item Size Engine Others Engine mounting nut bracket frame Engine mounting bolt engine bracket Radiator mounting bolt nut Torque converter mounting bolt 8EA MCV mounting bolt Steering unit mounting bolt Transmission mounting bolt nu...

Page 228: ... kgfÂm lbfÂft Hydraulic system Power train system 5 50D 60D 70D 7E 80D 7E 6 NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Item Size Engine Others Engine mounting bolt nut Radiator mounting bolt nut MCV mounting bolt nut Steering unit mounting bolt Hydraulic pump mounting bolt Transmission mounting bolt nut Torque converter mounting bolt Drive axle mounting bolt nut Steering axle mounting bolt nut Front whee...

Page 229: ...54 50Ü10 723Ü108 300Ü45 448Ü67 448Ü67 1555Ü239 18 1Ü3 6 93Ü22 kgfÂm lbfÂft Hydraulic system Power train system 5 50DF 60DF 70DF 7 8 NO 1 2 3 4 5 6 7 8 9 10 11 12 13 Item Size Engine Others Engine mounting bolt nut Radiator mounting bolt nut MCV mounting bolt nut Steering unit mounting bolt Transmission mounting bolt nut Torque converter mounting bolt Drive axle mounting bolt nut Steering axle moun...

Page 230: ...l in oil pan ÂPoor quality of fuel ÂReduce oil quantity ÂReplace with specified fuel ÂLack 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 ÂAddfuel ÂRepair ÂReplace ÂSee Electrical system ÂAdjust clearance ÂThermostat faulty ÂWater temperature gauge faulty ÂReplace ÂReplac...

Page 231: ...h 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 ÂRecharge battery ÂFaulty wiring Â...

Page 232: ...tioning 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 tra nsmission check and replace interfe ring parts ÂCheck engine stalling speed If necessary replace ÂCheck the inlet side joint or pipe If necessary retighten join...

Page 233: ...il 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 whee...

Page 234: ...cts and replace P 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 M...

Page 235: ...k 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 ÂDisass...

Page 236: ...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 ÂRetighten ÂBleed air ÂAdjust valve set pressure and check for specified oil pressure ÂRepair or replace ÂAdd oil ÂRepair ÂBleed air completely ÂRepair or repla...

Page 237: ...or replace ÂClean ÂRepair and add oil ÂBleed air ÂClean or replace ÂRepair by polishing or replace ÂReplace ÂRepair or replace ÂClean P Probable cause Remedy 3 Brake trailing 4 Brake chirps 5 Brake squeaks ÂPedal has no play ÂBrake shoe poorly sliding ÂWheel cylinder mal functioning ÂPiston cup faulty ÂReturn spring fatigued or bent ÂParking brake fails to return or out of adjustment ÂBrake valve ...

Page 238: ... replace ÂRepair or replace P Probable cause Remedy 7 Large pedal stroke 8 Pedal dragging ÂBrake out of adjustment ÂHydraulic line sucking air ÂOil leaks from hydraulic line or lack of oil ÂLining worn ÂShoe tilting or does not return compl etely ÂLining in poor contact with brake drum ÂTwisted push rod caused by improp erly fitted brake valve ÂBrake valve seal faulty ÂFlow control valve orifice c...

Page 239: ...s from 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 ÂForeig...

Page 240: ... EASE OF STARTING NOISE Set gear shift lever at N and pull parking brake Turn start switch to HEAT only 20 33DF 7 Turn start switch ON When heater signal lamp goes out turn key to START and start engine When engine starts check if it starts smoothly and if it makes any abnormal noise Refer to page 3 28 1 2 3 4 5 ö 1 2 3 4 1 1 2 Type Model OFF ON S T A R T HEAT D255OM10 1 D507OM301 160D7TA01T C 15D...

Page 241: ...tank is not within the normal range add water to the MAX line If antifreeze is being used pay careful attention to the ratio of antifreeze and water when adding coolant Check the coolant level all the times prior to daily initial operating of the engine ö ö Max Min 6 L255OM61 WHEN ACCELERATOR PEDAL IS DEPRESSED Check that accelerator pedal does not catch when depressed Check that engine speed incr...

Page 242: ... run the engine and check for oil leakage from the filter mount 1 2 3 8 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 SEE 8 SPECIFICATION 1 2 3 9 ENGINE OIL FILTER The condition of the oil filter element cannot be inspected from the outside so replace the engine oil filter ...

Page 243: ...ction when fan belt is pushed with a finger pressure at a point midway between fan pulley and alternator pulley If fan belt tension is not correct loosen alternator mounting nut and bolt of adjustment bar Move alternator to adjust belt tension Keep the fan belt free from oil and grease so that it can prevent the fan belt from slippage 1 2 3 4 ö A Drive pulley Fan pulley Alt pulley 11 12 D155ATA10 ...

Page 244: ...ck 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 Η Θ 1 2 ADJUSTMENT OF PEDAL Accelerator pedal Adjust the stopper bolt 1 so that pedal operation range is AÁ 1 A 1 3 D255ATA01 Model 15D 18D 20DA 7E 20D 25D 30D 33D 7E Operation range AÁ 20 9 22 6 Depress the accelerator pedal...

Page 245: ...n range AÁ 17 5Ü2 B Brake pedal ÂAdjust stopper bolt 1 so that pedal height is H ÂAdjust push rod 2 so that pedal play is idle stroke 3 2 H 1 P e d a l h e ig h t D155ATA04 Model 1 5 3 3 ton 35DF 7 3 5 4 5 ton 50DF 60DF 70DF 7 50D 60D 70D 7E 80D 7E H IDLE 160 130 140 113 35Ü1Á 1 3 2 3 2 5 Unit mm A 160D7TA01 1 H 160D7TA04 50D 60D 70D 7E 80D 7E 35Ü1Á ...

Page 246: ... 35DF 7 35D 40D 45D 7E 50D 7AE 50DF 60DF 70DF 7 50D 60D 70D 7E 80D 7E H IDLE 160 130 140 113 35Ü1Á 1 3 2 3 2 3 Model A 33 20 P 15 20 31 39 18 5 22 5 A Inching spool T M control valve Installed length of inching spool 20DFTA06 1 2 3 20 24m m H 50DEOM33 50D 60D 70D 7E 80D 7E 35Ü1Á Embossed letter Inner cap Cap Brake fluid reservoir 35 75mm 1 4 3 0in 20DFTA14 CHECK OIL LEVEL Stop the machine in a fla...

Page 247: ...through the dipstick hole at the top of the differential case When filling the oil in the differential case take to extreme care not to spill it on the floor It can cause to happen unexpected accidents such as personal injury due to slippage on the oil or fire If the oil is spilt on the floor wipe it off immediately 2 TORQUE FLOW Transmission Check the oil level with the oil gauge below the floor ...

Page 248: ...SEE 8 SPECIFICATION 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 8 SPECIFICATION 3 3 D35ATA15 STEERING AXLE Push axle 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 7mm ÂMou...

Page 249: ... be 30 60mm 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 1 5Á rear axle is bent Ask assistant to drive machine at minimum turning radius Fit bar and a piece of chalk at outside edge of counterweight to mark line of tu...

Page 250: ...depth that the pawl of the parking lever is hasped on the latch of the cowl so that it can prevent the parking brake from unexpected releasing problem of the parking operation ö Put the lever to the brake released position Pull the parking lever up to the specified stroke which is 23Áfor 35D 40D 45D 7E 50D 7AE 50DF 60DF 70DF 7 and 26Áfor 50D 60D 70D 7E 80D 7E respectively and the fix the adjust nu...

Page 251: ...lows Â35DS 40DS 45DS 7E 50DA 7E 87 6Á Â50DS 60DS 70DS 7E 97 7Á 1 2 3 Knob Adjust nut 2 1 Cable 3 5 8 0ton  Â35DS 40DS 45DS 7E 50DA 7E 50DS 60DS 70DS 7E 80D7TA24 When the parking lever is located to unlock position it should be adjusted the parking switch in order that the sensor of the switch may not touch with the counterpart plate and fix it ö ...

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