Hyundai 160D-9L Manual Download Page 224

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9-1

1. ENGINE SYSTEM

9 . TROUBLESHOOTING

Trouble symptom

Oil pressure warning lamp
fails to go out.

Radiator pressure valve
spouts steam.

Water temp gauge indicates
red range, on right.

Water temp gauge indicates
red range, on left.

Engine fails to start.

Engine emits whitish or bluish
smoke.

Abnormal sound heard.
(Fuel combustion or mechani-
cal sound)

Poor quality of fuel.

Overheating

Muffler interior damaged.

Excessively large valve clearance.

Replace with specified fuel.

See Symptom "Radiator pressure val-

ve spouts steam".

Replace

Adjust clearance.

Excessive quantity of oil in oil pan.

Poor quality of fuel.

Reduce oil quantity.

Replace with specified fuel.

Lack of fuel.

Air mixed in fuel system.

Fuel injection pump or nozzle defec-

tive.

Starting motor rotates slowly.

Engine compression insufficient.

Valve clearance out of adjustment.

Refill fuel.

Bleed air.

Replace.

See " Electrical system."

Contact dealer

Adjust clearance

Thermostat faulty.

Water temperature gauge faulty.

Replace

Radiator fin clogged or fin damaged.

Thermostat or water temp gauge fau-

lty.

Radiator filler cap loosening.

Clean or repair.

Replace

Retighten cap or replace packing.

Lack of cooling water or water lea-

kage.

Loosen fan belt.

Dust and scale accumulated in cool-

ing system.

Add water or repair.

Adjust belt.

Change water and clean the interior

of cooling system.

Low oil level in oil pan.

Oil filter element clogged.

Loose or worn oil pipe joint leaks oil.

Add oil.

Replace element.

Check and repair.

Probable cause

Remedy

Summary of Contents for 160D-9L

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

Page 2: ...on 4 1 2 Suggestion for new truck 4 3 3 Fuel safety practices 4 4 5 STARTING AND OPERATING PROCEDURES 5 STARTING AND OPERATING PROCEDURES 1 Before operating the truck 5 1 2 Check before operation 5 2 3 Check before starting engine 5 3 4 Seat adjustment 5 9 5 Starting from a safe condition 5 10 6 General starting and operating tips 5 11 7 Starting and stopping the engine 5 12 8 Warming up operation...

Page 3: ...system 7 50 9 Air conditioner and heater 7 51 10 Replacement and check 7 53 11 Handling truck in extremely hot places 7 63 12 Cold weather operation 7 64 13 Recommendation table for lubricants 7 65 14 Fuel and lubricants 7 66 8 SPECIFICATIONS 8 SPECIFICATIONS 1 Specification table 8 1 2 Specification for major components 8 2 3 Tightening torque 8 4 9 TROUBLESHOOTING 9 TROUBLESHOOTING 1 Engine syst...

Page 4: ... 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 operation every time you use your lift truck Let s join together to set high standards in safety Remember ...

Page 5: ...tial 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 Operator Daily Inspection Safety and Operating Checks A lift truck should always be examined by the operator before driving to be sure it...

Page 6: ...ing and adjusting The descriptions and specifications included in this manual were in effect at the time of printing The descriptions and specifications included in this manual were in effect at the time of printing HYUNDAI reserves the right to make improvements and changes in specifications or design without notice and without incurring obligation Please check with your authorized HYUNDAI dealer...

Page 7: ...ies 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 not equipped with a manual ask y...

Page 8: ...000 14 EC and EN 12053 are as followings EC REGULATION APPROVED Model 160D 9L 180D 9B LPA 71 2 dB LWA EU only 104 dB ÂThe value of vibrations transmitted by the operator s seat are lower than standard value of 2005 88 EC ...

Page 9: ...8 Fork positioner 39 Fork positioner 40 Lift 41 Tilt 42 Side shift 43 Fork positioner 44 Fork positioner 45 Fork positioner 46 Rotator 50 F R transfer 51 Rotator 52 Load chart 1 LOCATION 1 LOCATION Always keep these labels clean If they are lost or damaged attach them again or replace them with a new label SAFETY LABELS SAFETY LABELS 160D9LOM101 7 5 3 20 6 29 26 26 27 3 13 VIEW RADIATOR TOP CABIN ...

Page 10: ...th blocks blocks 1 1 25L7A0OM06 TEMPERATURE TEMPERATURE Item 8 This warning label is positioned on the top side of engine hood rear cover Coolant must be checked as specified in Coolant must be checked as specified in the maintenance chart the maintenance chart 2 2 25L7A0OM10 RADIATOR RADIATOR ltem 7 This warning label is positioned on the top side of engine hood rear cover It forbids to open the ...

Page 11: ... 5 3 for the regulated tire Refer to page 5 3 for the regulated tire air pressure A and B air pressure A and B 92AT 00830 kgf cm A PSI B 6 6 25L7A0OM08 HOOK HOOK Item 5 This warning label is positioned near the lifting bracket on the engine hood rear cover and the top side of mast LH and RH Refer to page 5 35 for safe loading Refer to page 5 35 for safe loading procedures procedures 7 7 92AM 00630...

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

Page 13: ...hrough operation of the appropriate control when the operator is not in the normal position This forklift equipped with an operator existence sensing system per ANSI ASME B56 1 7 21 10 and 7 21 11 Please review Operator s manual for safe operation of forklift Power travel movement of the truck shall be possible only if the operator is in the normal operating position Transmission will automaticall...

Page 14: ...g handle Lean the body to the opposite direction in order to avoid severe injury or death when the truck is tipped over Refer to page 3 3 Refer to page 3 3 1 2 3 4 5 6 7 91B3 01201 13 13 1 2 3 4 5 6 7 CABIN TILT UP DOWN CABIN TILT UP DOWN Item 16 This warning label is positioned on the left side of frame 92FT 40720 14 14 92FT 40720 When tilting cab for service the cab must be fully extended up or ...

Page 15: ...50D7EFW04 NOISE LEVEL NOISE LEVEL Item 22 This warning label is located on the right side of the engine hood 16 16 91FU 00200 FIRE EXTINGUISHER FIRE EXTINGUISHER Item 32 This label is located on the rear right of the cabin inside Read and understand the instructions Read and understand the instructions adhered decal on the fire extinguisher adhered decal on the fire extinguisher 17 17 91B1 01600 9...

Page 16: ...rous if it is handled in extremely dangerous if it is handled in the wrong way Always observe the the wrong way Always observe the following precautions following precautions Never make any hole in the accumulator Never make any hole in the accumulator expose it to flame or fire expose it to flame or fire Do not weld anything to the accumulator Do not weld anything to the accumulator When carrying...

Page 17: ...ch the cabin tilting cylinder head during the operation Refer to page 3 43 for air compressor Refer to page 3 43 for air compressor switch switch 22 22 1 2 3 4 5 6 7 AIR COMPRESSOR TANK AIR COMPRESSOR TANK Item 23 This label is positioned on the top side of the air tank Do not touch the cylinder head during the Do not touch the cylinder head during the operation or it may cause severe burn operati...

Page 18: ...erves as an alternate exit exit To remove rear window pull the ring and To remove rear window pull the ring and push out the glass push out the glass 25 25 91Q6 07280 91Q6 07280 91Q6 07280 SCR SCR Item 18 This label is located on the left side of the frame Do not touch the aftertreatment device or Do not touch the aftertreatment device or it may cause severe burn When the it may cause severe burn ...

Page 19: ... NUMBER It s shown on front of the right side frame 1 1 160D7SM02 ENGINE SERIAL NUMBER ENGINE SERIAL NUMBER The numbers are located on the engine name plate 2 2 Important safety hint Important safety hint It indicates matters which can cause the great loss on the truck or the surroundings It indicates matters which can cause the great loss on the truck or the surroundings It indicates the useful i...

Page 20: ...rication 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 160D9LOM02 1 SAFETY HINTS 1 SAFETY HINTS 1 DAILY INSPECTION 1 DAILY INSPECTION ...

Page 21: ...wear safety equipment when required D35AOM05 Don t mix drugs or alcohol with your job Don t block safety or emergency equipment 160D9LOM04 D35AOM02 Don t smoke in NO SMOKING areas or when refueling D35AOM06 2 DO S AND DON TS 2 DO S AND DON TS ...

Page 22: ... in rainy day Exclude the truck equipped cabin Exclude the truck equipped cabin 160D9LOM07 Exhaust gas is dangerous Do not operate the truck at the inhouse if possible Provide adequate ventilation when working in a closed space 160D9LOM08 ...

Page 23: ...LTS 3 SEAT BELTS Seat belts can reduce injuries Seat belts can reduce injuries 160D9LOM11 Always buckle up for the truck equipped Always buckle up for the truck equipped with safety belt with safety belt 160D9LOM09 ...

Page 24: ...1 5 160D9LOM12 160D9LOM14 4 NO RIDERS 4 NO RIDERS The operator is the only one who should be on a truck Never transport personnel on the forks of a lift truck 1 2 ...

Page 25: ...dway you do Sound your horn at all intersections or blind spots 160D9LOM05 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 160D9LOM06 5 PEDESTRIANS 5 PEDESTRIANS 1 2 3 ...

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

Page 27: ...ks D255OM17A There is special equipment to raise people for overhead work DO NOT USE LIFT TRUCKS 160D9LOM14 Always lower the load slowly Raise and lower with mast vertical or tilted slightly back Never forward 160D9LOM17 7 FORK SAFETY 7 FORK SAFETY ...

Page 28: ...e the mast as a ladder Don t use the mast as a ladder 160D9LOM62 Never try to repair the mast carriage Never try to repair the mast carriage chain or attachment by yourself Always chain or attachment by yourself Always get a trained mechanic get a trained mechanic 160D9LOM63 8 PINCH POINTS 8 PINCH POINTS ...

Page 29: ...160D9LOM18 When handling 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 160D9LOM25 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 160D9LOM26 9...

Page 30: ...SLOPES AND INCLINES 10 GRADES RAMPS SLOPES AND INCLINES 160D9LOM30 160D9LOM33 Unloaded Forks downgrade Loaded Forks upgrade 1 2 Never turn on a grade either loaded or unloaded Never turn on a grade either loaded or unloaded ...

Page 31: ...ngitudinal 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 collisions An off dock type of tip over can occur if the truck is steered too close to the dock edge dri...

Page 32: ... as illustrated right 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 Your chances for survival in a tip over are better if you stay with the truck in your better if you stay with the truck in your seat seat 3 1 2 4 ...

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

Page 34: ...truck Be sure the travel control is in NEUTRAL 160D9LOM42 Lower forks fully to the floor and tilt forward ON OFF START 1 2 160D9LOM44 Put the parking brake switch in LOCK position Position 1 Release Position 2 Lock Turn start switch to OFF position 13 PARKING 13 PARKING 1 2 3 4 5 50D9OM37 ...

Page 35: ...el check around truck for oil leakage 160D9LOM47 Keep away from fire when adding fuel or during operation DIESEL 110D9OM48 After adding fuel wipe off any fuel spilled on the truck 160D9LOM49 14 REFUELING 14 REFUELING 1 2 3 ...

Page 36: ...1 17 When getting on or off the truck use the step provided 160D9LOM50 Do not jump up or down from the truck 160D9LOM52 15 STEP 15 STEP 1 2 ...

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

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

Page 39: ...Never carry loose or uneven material 160D9LOM53 Center wide loads 160D9LOM55 Stack and band loose material D35AOM41 Avoid sudden braking or starting When the truck is loaded do not drive at When the truck is loaded do not drive at maximum speed maximum speed 160D9LOM56 2 OPERATING HAZARDS 2 OPERATING HAZARDS 1 LOOSE LOADS 1 LOOSE LOADS ...

Page 40: ...A long load reduces the capacity of the A long load reduces the capacity of the truck Know and understand your truck truck Know and understand your truck load rating load rating 160D9LOM57 When turning be sure the rear end of When turning be sure the rear end of the truck does not swing into racks the truck does not swing into racks posts etc Watch for pedestrians beside posts etc Watch for pedest...

Page 41: ...uck over or spill a load truck over or spill a load 160D9LOM74 Slow down before turning Slow down before turning The truck can tip over The truck can tip over 160D9LOM46 Turn too sharp with a raised load and Turn too sharp with a raised load and your truck can tip even at slow speeds your truck can tip even at slow speeds Travel with a load raised only when Travel with a load raised only when remo...

Page 42: ... Slack chains mean rail or carriage hang Slack chains mean rail or carriage hang up up Raise the forks before you move or Raise the forks before you move or broken chains can result broken chains can result In case forks with loads are stuck while In case forks with loads are stuck while lowering the mast lift the mast again and lowering the mast lift the mast again and prevent chains from being s...

Page 43: ... near the electrical lines is The operating near the electrical lines is very dangerous very dangerous Operate within safe working permitted as Operate within safe working permitted as below below 9 CAUTION FOR ELECTRICAL LINES 9 CAUTION FOR ELECTRICAL LINES 160D9LOM76 160D9LOM77 If the truck touches the electric power If the truck touches the electric power lines keep sitting on the operator s se...

Page 44: ...2 6 Never permit any persons to stand or pass under lifted load 10 LIFTING LOADS 10 LIFTING LOADS 160D9LOM58 160D9LOM60 Never use wire rope to lift a load ...

Page 45: ...hout shifting it in the netural position it can be overturned the forklift due to unstabled load When lifting or lowering the side shift with load it should be observed that the load is moved into the netural position 160D9LOM78 Never operate the side shift while the forks are not equipped with supports such as a load table for the load Never travel the forklift while the side shift is moved with ...

Page 46: ... the ground Never move the levers to operate the fork Never move the levers to operate the fork positioner suddenly and quickly positioner suddenly and quickly It can be caused to drop the load It can be caused to drop the load 160D9LOM79 12 FORK POSITIONER 12 FORK POSITIONER ...

Page 47: ...nt wheel 9 Head lamp fender 10 Tilt cylinder 11 Work lamp mast 12 Rear view mirror 13 Rear wheel 14 Bonnet 15 Counterweight 16 Rear combination lamp 17 Silencer 18 Air conditioner opt 19 Rear work lamp 20 Cabin 1 2 3 4 5 6 7 8 9 10 11 13 12 14 15 16 17 18 19 20 160D9LOM54 3 KNOW YOUR TRUCK 1 GENERAL LOCATIONS ...

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

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

Page 50: ...l Operator seat Brake pedal Handsfree opt Remote controller opt The ergonomically designed console box and suspension type seat provide the operator with comfort ELECTRONIC MONITOR SYSTEM The centralized electronic monitor system allows the status and conditions of the truck to be monitored at a glance It is equipped with a safety warning system for early detection of truck malfunction 1 2 160D9LC...

Page 51: ...h Fingertip Cigar lighter Switch board Aircon heater switch opt Cluster Steering wheel Gear selector lever Inching pedal Multi function switch Accelerator pedal Operator seat Brake pedal Handsfree opt Remote controller opt 160D9LCD01 1 Fingertip type Â ...

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

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

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

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

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

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

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

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

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

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

Page 62: ...enu left up right down Decrease Increase input value When the warning and pilot lamps occur over six you can display next lamps by push the button Ķ Η Θ Η Η Θ Ι Buzzer stop ESC button 1 Menu button Move button 2 3 CLUSTER BUTTON 4 Menu button Camera Enter button Move button Buzzer stop ESC button 160D9LCD121 50D9CD24 50D9CD23 50D9CD22 50D9CD25 Enter button Change the camera screen on main This but...

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

Page 64: ... history Maintenance management Signal statue User password change Opening of communication Current history logged history and delete logged fault Replacement Change interval oils and filters Display information of sensors User password change 5 10 digit Orbcomm GPS antenna 6 LCD adjustment Time setting Unit setting Language setting AS phone number ESL password change Maintenance management LCD br...

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

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

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

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

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

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

Page 71: ...hold down the manual button Automatic The fan rotate in reverse direction at pre set interval Interval 30 minutes 5 hours Time 30 seconds 5 minutes Refer to the page 3 43 for the cooling fan control switch Â Â ö Cooling fan reverse mode Π 180D9CD101 1 180D9CD103 1 ...

Page 72: ... 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 Ability to set up the maximum Pull Push Min Max value and neutral value Mid of lever Finger Tip lever set up about 0 5V 2 5V 4 5V You must be to move with actual Lever Unit V ex Min 0 48 Mid 2 52 Max 4 52 Â Â ...

Page 73: ...e neutral Lever state 2 5V ex If you set up the Upper 0 26 Lower 0 24 Lever operating range will be Upper zone 2 76V 2 5 0 26 4 5V Lever Max value Lower zone 2 26V 2 5 0 24 0 5V Lever Min value Â 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 ...

Page 74: ... of movements according ot the current value Unit Over 110D 9 only mA Under 80D 9 Only ex If the Max value increase the maximum speed will also increase If the Min value increase the minimum speed will also increase Â 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 ...

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

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

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

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

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

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

Page 81: ...3 32 Show the maintenance information replacement cycle elapsed time change count alarm information Â Maintenance management Ξ 50D9CD131 50D9CD132 1 50D9CD133 1 ...

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

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

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

Page 85: ...n control switch opt In decrement switch SCR cleaning switch Seat heater switch opt Hazard switch opt Parking brake switch Transmission shift mode switch Power standard switch Rear wiper washer switch Top wiper washer switch opt Air compressor switch opt Center horn button Multi function switch Start switch Cover 160D9LCD06 ÂRemote control lever type ...

Page 86: ...witch Cooling fan control switch opt In decrement switch SCR cleaning switch Seat heater switch opt Hazard switch opt Parking brake switch Power standard switch Rear wiper washer switch Top wiper washer switch opt Air compressor switch opt Cover Master switch Center horn button Multi function switch Start switch 160D9LCD06 1 ÂFingertip type ...

Page 87: ...verheat and may cause the brake system to go out of order 4 1 2 ö MAIN LIGHT SWITCH This switch is used to operate the head light by one steps First step Clearance lamp and cluster illumination lamp comes ON Also all of the pilot lamps of switches come ON Second step Head lamp comes ON and head lamp pilot lamp comes ON Refer to page 3 41 for head lamp 5 1 50D9CD45 START SWITCH There are three posi...

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

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

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

Page 91: ...inated HEST lamp will be illuminated during the entire SCR cleaning Refer to the page 3 11 for details This switch return to the OFF position when released the manual position Θ SCR Selective Catalytic Reduction 1 2 3 4 SCR CLEANING SWITCH 1 2 OFF 50D9OM21A 18 刮刯侍侍侍刮刯到 REAR WIPER WASHER SWITCH This switch is used to operate the wiper and washer on the rear of the cab The washer liquid is sp...

Page 92: ...rse according to set up interval and time of the cooling fan reverse mode ö Refer to page 3 29 to set of the cluster OFF Only forward rotation is possible MANUAL The fan rotates reverse only while pressing this position If release the switch return to the OFF position The reverse rotation pilot lamp lights up on the area of the warning and pilot lamp of the LCD when the cooling fan is operated to ...

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

Page 94: ...2 Tilt forward Tilt backward TILT LEVER 2 50D9CD16 ö Tilt forward Push the lever forward to tilt mast forward Tilt backward Pull the lever back to tilt mast backward Holding When the lever is released tilting action stops Forward and backward tilting speeds are controlled by tilt lever and accelerator pedal 1 2 3 ö LH movement Push the lever forward to move the left hand for the side shift RH move...

Page 95: ... SIDE SHIFT WITH FORK POSITIONER Fork positioner synchronizer type 4 Η Θ 50D9CD19 1 1 LH fork movement Push the lever forward to move outward for the LH fork Pull the lever backward to move inward for the LH fork Outward Inward Η Fork positioner independent type 2 50D9CD21 1 RH fork movement Push the lever forward to move outward for the RH fork Pull the lever backward to move inward for the RH fo...

Page 96: ...lever the truck moves forward but pulling the gear selector lever the truck moves backward If you turn the gear selector lever forward the truck increases the speed but if you turn the gear selector lever backward the truck reduces the speed 1 2 3 GEAR SELECTOR LEVER 5 Acceleration Deceleration Forward Backward 110D9CD36 This pedal controls the engine speed The engine speed will increase in propor...

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

Page 98: ...pleasant operation against outside temperature and defrost on window glass 8 AIR CONDITIONER AND HEATER 160D9LCD90 AIR CONDITIONER BUTTON When you push this button air conditioner system is operated Determines whether to perform a cooling function of air conditioner Η Pilot lamp ON Air conditioner operation Θ Pilot lamp OFF Fan only The AUTO pilot lamp ON when this button is pushed 1 2 ö 50D9CD50 ...

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

Page 100: ...r Front Radio and USB player Cigar lighter Handsfree option Remote controller option 12V socket Seat TCU MCU ECM Fuse box Fingertip type Handsfree option Remote controller option 12V socket 9 OTHERS 160D9LCD09 ...

Page 101: ...73033CD49 R5573CD49 TRANSMISSION CONTROL UNIT TCU ENGINE CONTROL MODULE ECM MACHINE CONTROL UNIT MCU 3 4 5 The control unit is shifting the required speeds fully automatically under consideration of the following criteria Â Gear selector lever position Â Driving speed Â Load level The engine control module ECM is the control center of the engine system It consists of electronic parts and controls ...

Page 102: ...IC microphone 18 Aux connector ÿFRONT PANEL PRESENTATION ÿBASIC FUNCTIONS 1 Audio selection button Audio selection knob 2 Power and volume button 3 Mode button select RADIO USB AUX 4 UP DOWN tuning button 5 Preset memory button 1 DISP ID3 v2 display 6 Preset memory button 2 SCN File scan 7 Preset memory button 3 RPT Repeat play selector 8 Preset memory button 4 RDM Random play selector SEL MODE 1 ...

Page 103: ...matically return to the normal indication in 5 seconds after the last adjustment or when another function is activated Treble control To adjust the treble level first select the treble mode by pressing the SEL button until TREBLE indication appears on the LCD display Within 5 seconds of choosing the treble mode turn selection knob right left to adjust the treble level as desired The treble level w...

Page 104: ... socket USB Ear HP Indicator lamp 12V socket USB Ear HP Mobile phone storage box 300D9CD51 21093CD51A 1 Mobile phone can be stored when call by handsfree 刮 HANDSFREE OPTION 7 This socket is used to charging the mobile phone USB socket 刮 2 This can be used protect you privacy calling by using ear phone The mobile phone must be connected handsfree jack socket Private call jack socket 刮刯 3 USB Ear H...

Page 105: ...nect the jack cable when call by handsfree Use the special adapter when jack cable is not interchangeable Check the jack type of mobile phone before use 刮刯到 This lamp is turned ON when the handsfree mode selected Indicator lamp 刮 5 USB Ear HP 21093CD51E ...

Page 106: ...YUNDAI and set connect with Bluetooth on the mobile phone Default password 0000 The Bluetooth pairing is made the LCD screen shows CONNECTED Once the Bluetooth pairing is made they will be automatically connected after 20 seconds when start switch ON When you want to deactivate the pairing press and hold the button for more than 3 seconds then you can hear beep sounds twice and the function will b...

Page 107: ...free ON or OFF This switch is turned to right the handsfree volume is increased over 7 steps If it is turned to left volume will be decreased This switch adjust the audio volume when selected audio mode Power and volume switch Η Θ Ι ö 1 This button is to select the handsfree mode or audio mode ÂLamp ON Handsfree mode TEL MUTE displayed ON audio LCD ÂLamp OFF Audio mode Mode change button Η 2 This ...

Page 108: ...ation of higher frequency and the next song of the MP3 Turn a station of lower frequency and the previous song of the MP3 Η Θ Mute button Short press this button to mute or cancel the mute silence while broadcasting Η 6 Mode button 7 Press the mode button to select the desired mode Radio Ą MP3 Ą AUX The LCD displayed each mode Η Θ ö This MIC transfers user voice to receiver of the call when making...

Page 109: ...io handsfree You can make a call to external worker without holding the radio by hand The radio is not installed to the truck Η Θ Ι ö 55I3CD31H Talk button The call is connected while pressing this button when TALK button is activated Unlike mobile phones when you want to talk through the radio you need to press the button Push to talk method While one is talking through the radio the other party ...

Page 110: ...draulic oil may be hot or under pressure When inspecting a lift truck wear safety Leaking hydraulic oil may be hot or under pressure When inspecting a lift truck wear safety glasses and do not check for leaks with bare hands glasses and do not check for leaks with bare hands VISUAL CHECKS VISUAL CHECKS First perform a visual inspection of the truck and its major components Walk around your lift tr...

Page 111: ...ges meters and indicator lights Service brakes inching pedal and parking brake Hydraulic controls lift tilt and auxiliary If installed Accelerator pedal Gear selector lever Steering system Lift mechanism and any attachments When the functional check are completed follow the standard shutdown procedures standard shutdown procedures given in Section 5 Starting and operating procedures Starting and o...

Page 112: ...uel Check regularly the lubrication and fill Grease daily all lubrication points Tighten bolts Warm up the truck fully before operation Check the gauges during operation Check if the truck is operating normally during operation Replace following after initial hours of operation Replace following after initial hours of operation 4 4 Avoid excessive operation for initial 100 hours 2 SUGGESTION FOR N...

Page 113: ...refueling safe distance while refueling 100D7OM106 D35AOM106 USE CLEAN PROPERLY MARKED FUEL CANS CLEAN UP SPILLS D35AOM106 DANGER DIESEL FLAMMABLE D35AOM106 Make sure that the fuel oil cans are kept Make sure that the fuel oil cans are kept cleaned and attached safety indication or cleaned and attached safety indication or letters on the can letters on the can Wipe off the spilt fuel oil immediate...

Page 114: ...r lift truck before operating at the start of each shift Before putting your truck to 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 use check the operation of the controls and all systems Protect yourself Do not operate truck without closing the cabin door or without fastening seat Protect yo...

Page 115: ... realize maximum service life for your truck The numbers on the inspection chart show the order of inspection These numbers correspond to the check item numbers given on the next pages Hang a caution sign on the truck for example Do not start Do not start or maintenance in progress maintenance in progress This will prevent anyone from starting or moving the truck by mistake 2 1 Oil leakage 2 Tire ...

Page 116: ...g or servicing tires and rims could cause the tire to explode causing serious injury or damage The tires and rims should always be serviced or changed by trained personnel using the correct tools and procedures For details of procedures contact your HYUNDAI dealer or tire repair shop If there is any deformation damage or wear of the rim or any doubt about the condition always replace the rim Never...

Page 117: ...adding water At the operating temperature the engine cooling water is at At the operating temperature the engine cooling water is at high temperature and pressure so it is dangerous to try to high temperature and pressure so it is dangerous to try to open the surge tank cap Wait until the radiator is cool open the surge tank cap Wait until the radiator is cool enough to be touched by hand before o...

Page 118: ... Uneven excessive rib wear Exposed belt cords Glazing high heat If any of the above conditions are present If any of the above conditions are present the belt is unacceptable for reuse and must the belt is unacceptable for reuse and must be replaced be replaced 1 2 OK NOT OK 120096MA42 120096MA43 2609A6MA47 CHECK BATTERY CHECK BATTERY Check battery and recharge or replace the battery if necessary ...

Page 119: ...allow hot oil or components to contact skin 1 Normal Cap L H 160D9LOM113 CHECK HYDRAULIC OIL LEVEL 8 Rest fork on ground and stop engine Check the oil level from the level gauge of hydraulic oil tank In accordance with the mast equipped the oil level differs 1 2 3 Upper limit Level gauge Lower limit 160D7MA14 Model Gauge U S gal V mast TS mast 160D 9L 180D 9B Lower limit 182 48 1 V300 700 TS395 75...

Page 120: ...ank If the level of the washer liquid is LOW add the washer liquid In cold winter the washer liquid is LOW add the washer liquid In cold winter days or water The capacity of the tank is 1 liter days or water The capacity of the tank is 1 liter 1 1 MULTI FUNCTION SWITCH MULTI FUNCTION SWITCH 10 10 O J Ⅰ Ⅱ 73033CD29 Turning switch Turning switch This switch is used to warn or signal the turning dire...

Page 121: ...e plug of planetary gear in parallel to the ground the ground When checking the oil level place the parking When checking the oil level place the parking brake switch in the LOCK position and fix the brake switch in the LOCK position and fix the tires with blocks tires with blocks As the truck is hot after operation wait until As the truck is hot after operation wait until the temperature has drop...

Page 122: ...regardless of appearance 1 SEAT ADJUSTMENT SEAT ADJUSTMENT The seat is adjustable to fit the contours of the operator s body It will reduce operator fatigue due to long work hours and enhance work efficiency G B D E F A C Forward Backward adjustment Forward Backward adjustment Pull lever A to adjust seat forward or backward Upward Downward adjustment Upward Downward adjustment Push or pull the hei...

Page 123: ...rols function All controls are in neutral or other correct position The truck has received its daily inspection and ready and safe to operate 1 Put the gear selector lever in the NEUTRAL position before starting The truck should start only in the NEUTRAL position If it starts in gear have the truck serviced 2 LOCK Forks are down Parking brake switch 160D9LOM31 Forward Backward Neutral 110D9OM45 5 ...

Page 124: ... 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 leaks Do not operate the engine at speeds above idle for more than brief periods without a load Do not run the engine at maximum power continuously...

Page 125: ...ly above 3 lamps remain ON 1 2 3 7 STARTING AND STOPPING THE ENGINE 7 STARTING AND STOPPING THE ENGINE 1 1 Gear selector lever Parking brake switch 1 3 2 160D9LOP03 STARTING ENGINE IN NORMAL TEMPER STARTING ENGINE IN NORMAL TEMPER ATURE ATURE Sound the horn to warn the surroundings Sound the horn to warn the surroundings after checking if personnel or obstacles are in after checking if personnel o...

Page 126: ...starting the engine Travelling the truck or operation of the attachments could be caused shut down of the engine In the event of the winter season the fuel oil happens WAX from 6 In the event of the winter season the fuel oil happens WAX from 6 C C When the ambient temperature is below 6 When the ambient temperature is below 6 C do not operate the truck under high load C do not operate the truck u...

Page 127: ...lem as required as required Check engine exhaust color 5 Check fuel tank level 6 Colorless light blue Black White Exhaust gas color Criteria OK Check for incomplete combustion Check for oil leakage If the indicator points to F the tank is full If the indicator enters the E range refill the fuel tank immediately Do not operate the truck below this level Do not use low quality fuel or fuel mixed wit...

Page 128: ...cknut and turn the adjust nut Equalize tension on the lift chain Do not put hands into the mast Do not put hands into the mast SEAT BELT WARNING LAMP ENGINE CHECK WARNING LAMP FUEL LOW LEVEL WARNING LAMP T M OVERHEAT WARNING LAMP E G COOLANT OVERHEAT WARNING LAMP SCR CLEANING WARNING LAMP DEF LOW WARNING LAMP WARNING LAMP ENGINE STOP E G OIL PRESSURE WARNING LAMP WATER IN FUEL WARNING LAMP BRAKE O...

Page 129: ...as cooled down engine life may be greatly has cooled down engine life may be greatly shortened Consequently do not abruptly shortened Consequently do not abruptly stop the engine apart from an emergency stop the engine apart from an emergency In particularly if the engine has overheated In particularly if the engine has overheated do not abruptly stop it but run it at medium do not abruptly stop i...

Page 130: ...ly and tilt the mast forward to the stroke end to relieve hydraulic pressure Do not leave hydraulic pressure relieved for Do not leave hydraulic pressure relieved for more than 30 seconds more than 30 seconds Tilt back to the stroke end to relieve hydraulic pressure Do not leave hydraulic pressure relieved for Do not leave hydraulic pressure relieved for more than 30 seconds more than 30 seconds R...

Page 131: ...dgement exercised by the operator speed loading dynamic and static forces and the judgement exercised by the operator Trucks equipped with attachments behave as partially loaded trucks even when operated 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 without a load on the atta...

Page 132: ...ly The further you depress the inching pedal the more the driving clutch slips reducing travel motion With the inching pedal fully depressed the brakes fully engage You operate the inching pedal with your left foot for precise control of travel speed while you operate the accelerator pedal together with the lift control to vary lift speed 110D9OM95 160D7OM131 160D7OM132 160D7OM133 2 2 ACCELERATOR ...

Page 133: ...o move the truck Changing direction and speed Changing direction and speed The gear selector lever is designed for the mounting on the left side of the steering column The positions speeds 1 to 3 are selected by a rotary motion the driving direction Forward F Neutral N Reverse R by tilting the gear selector lever A neutral lock is installed as protection against inadvertent drive off Position N Ge...

Page 134: ...g does not function with engine OFF Steering does not function with engine OFF Precautions when driving Precautions when driving If the monitor warning lamp lights up put the gear selector lever in the neutral position and stop the truck Stop the engine after running it at low idling Then resolve any problems regarding operation of the truck When operating the truck if the load is lighten rapidly ...

Page 135: ...5 minutes Stopping the truck Stopping the truck Press the brake pedal to stop the truck Put the gear selector lever in the neutral position Put the parking brake switch in LOCK position 6 6 Gear selector lever Parking brake switch 160D9LOP14 160D9LOP07 ...

Page 136: ...pped Check the leakage of oil and water the work equipment and the exterior of the truck Refill the fuel tank Remove any debris inside of the engine room and attached to the truck 7 7 8 8 Gear selector lever Parking brake switch Low idling for 5 minutes 160D9LOP20 TRAVELING ON A SLOPE TRAVELING ON A SLOPE Never travel down a slope in neutral Lower the forks 15 20 cm 6 8 in to the ground Never turn...

Page 137: ...tection to the operator from falling objects but cannot protect against every possible 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 be...

Page 138: ... gear state It makes the brake oil overheated due to excessive brake operation It makes the brake oil overheated due to excessive brake operation PRACTICE SAFE OPERATION EVERY TIME YOU USE YOUR TRUCK PRACTICE SAFE OPERATION EVERY TIME YOU USE YOUR TRUCK Careful driving and operation is your responsibility Be completely familiar with all the safe driving and load handling techniques in this Operato...

Page 139: ...aised 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 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 malfunctions in any way or becomes stuck in a raised position operate the l...

Page 140: ...de easier Unlock the fork locking pins Position the forks by pushing them away from you Secure the fork locking pins 2 2 160D9OM134 LOAD ON FORKS LOAD ON FORKS Do not elevate the load with one fork Loading with one fork cause the tip over serious injury or death of operator The work can cause the height difference between both fork tips 1 3 3 160D9LOM137 Do not elevate the load with the ends of th...

Page 141: ...ever possible 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...

Page 142: ... than the load move the tips partially under the 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 t...

Page 143: ...rther lift the load 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 Lower the forks slightly to clear the load pallet Tilt the forks forward slightly if necessary D35AOM137 D35AOM1...

Page 144: ...oad 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 minimum back tilt...

Page 145: ... 160D9LOM31 Low idling for 5 minutes 160D9LOP07 IN ADDITION WHEN LEAVING THE TRUCK IN ADDITION WHEN LEAVING THE TRUCK UNATTENDED UNATTENDED Tilt the mast forward until the forks are level and flat on the ground Let the engine run at idle speed Turn the start switch to the OFF position and remove the key Block the wheels if the truck must be left on an incline or you have any doubt about the truck ...

Page 146: ...LOP17 1 1 1 2 3 4 5 6 DURING STORAGE DURING STORAGE Operate the engine and move the truck for a short distance once a month so that a new oil film will be coated over movable parts and component surfaces Remove and storage the battery at the same time The above operations should be performed in The above operations should be performed in the open If they have to be performed inside the open If the...

Page 147: ...ck and the loading dock Ensure that the transporter cannot move by applying the brake and putting blocks under the wheels Put the gear selector lever in the NEUTRAL position Fix the loading ramps securely so that the centers of the transporter and truck are aligned The loading ramps should be of sufficient width length and thickness to permit safe loading or unloading After checking that the truck...

Page 148: ...cation of the truck when you are going to hoist the truck Use long wire rope and stay to keep the distance with the truck as it should avoid touching with the truck body Put a rubber plate where the wire rope contact with the truck s body to prevent damage Place crane on the proper place Install the wire rope and stay like the illustration Make sure wire rope is proper size Make sure that the truc...

Page 149: ...truck while working around it When possible raise the carriage forks on the disabled truck about 300 mm 12 in from the floor 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 av...

Page 150: ... cause injury or death to personnel near it injury or death to personnel near it Park the disabled truck in authorized areas only Fully lower the forks to the floor put the gear selector lever in the NEUTRAL position and turn the staring switch to the OFF position Set the parking brake switch ON position Remove the start switch and when necessary block the wheels to prevent the truck from rolling ...

Page 151: ...lockwise until the brake disc is free For the emergency release is an actuation torque of 4 1 For the emergency release is an actuation torque of 4 1 kgf m kgf m 29 5 29 5 lbf ft lbf ft respectively 7 1 respectively 7 1 kgf m kgf m 51 6 51 6 lbf ft lbf ft required required Mount the lock nut 5 and the screw cap 4 and tighten both as far as possible manually protection against dirt Now the truck do...

Page 152: ... illuminated or has a bright color Install a new battery BATTERIES EMIT EXPLOSIVE GAS Do not smoke or have open flames or sparks in BATTERIES EMIT EXPLOSIVE GAS Do not smoke or have open flames or sparks in battery charging areas or near batteries An explosion can result and cause injury or death battery charging areas or near batteries An explosion can result and cause injury or death Hydrogen ga...

Page 153: ...eys fans or other parts that move Do not touch hot manifolds that can cause sever burns Start the engine on the jumper truck and run the engine at a moderate speed for a minimum of five minutes Start the engine on the stalled truck Follow the starting instructions in section 5 Starting and Operating Procedures in this manual Be sure that the engine is at idle speed before disconnecting the jumper ...

Page 154: ...this daily examination is to check for any obvious damage and maintenance problems and to have minor adjustments and repairs made to correct any unsafe condition In addition to the operator s daily inspection HYUNDAI recommends that the owner set up and follow a periodic planned maintenance PM and inspection program Performed on a regular basis by trained personnel the program provides through tru...

Page 155: ...ty glasses Wear a safety hard hat in industrial plants and in special work areas where protection is necessary and required Properly ventilate work area vent exhaust fumes and keep shop clean and floors dry Avoid fire hazards and have fire protection equipment present in the work area Do not use an open flame to check for level or leakage fuel electrolyte or coolant Do not use open pans of fuel or...

Page 156: ... 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 Always put oak blocks under the carriage and mast rails when it is ne...

Page 157: ...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 158: ... for normal operation operation in clean ware houses The indicated intervals are intended for normal operation The operating condition classifications are The operating condition classifications are NORMAL OPERATION NORMAL OPERATION Eight hour material handling mostly in buildings or in clean open air on clean paved surfaces SEVERE OPERATION SEVERE OPERATION Prolonged operating hours or constant u...

Page 159: ... 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 normal condition after complation of service For more...

Page 160: ...Tilt cylinder hose Every 1 to 2 years 8 Side shift cylinder hose Every 1 to 2 years 9 Master cylinder and wheel cylinder caps dust seals Every 1 years 10 Brake hose or tube Every 1 to 2 years 11 Brake reservoir tank tube Every 2 to 4 years 12 Intake air line Every 2 years 13 Coolant hose and clamps Every 2 years EMISSION RELATED COMPONENTS WARRANTY USA AND CANADA ONLY Hyundai shall have obligation...

Page 161: ...orque converter 11 Engine 12 Steering cylinder 13 Hydraulic pump 14 Steering axle 15 Rear wheel 16 Air cleaner 17 Counterweight 18 Radiator 19 Seat 20 Cabin 21 Steering wheel 22 Silencer 23 Drive shaft 24 Precleaner 25 Aftertreatment device 26 Air conditioner opt 22 7 8 20 19 23 9 10 11 15 12 14 24 17 18 13 21 1 2 3 6 5 4 16 25 26 160D9LOM21 MAJOR COMPONENTS LOCATION MAJOR COMPONENTS LOCATION 1 1 ...

Page 162: ...ck Adjust Replace Check Add Check Repair or Replace Check Repair or Replace Check Repair or Replace Check Repair or Replace Check Repair or Replace Check Replace Check Repair or Replace Check Repair or Replace Check Repair or Replace 7 15 7 15 7 17 7 61 7 48 3 7 5 14 3 9 7 20 7 22 3 9 7 29 7 37 5 5 7 32 4 2 7 57 4 2 7 57 4 2 7 57 4 2 7 57 4 2 7 58 10 4 7 59 7 59 5 14 Check items Service Remarks Tr...

Page 163: ...brication Lift chain Mast roller and pin Lift cylinder rod end Lift cylinder tube end Tilt cylinder rod end Tilt cylinder tube end Steering cylinder rod end Steering cylinder tube end Attachment option cylinder rod end Attachment option cylinder tube end Steering axle wheel bearing Pedal pivot Check Add Check Clean Check Add Check Replace Check clean Check clean Check Lubricate Check Lubricate Che...

Page 164: ...nsioner Brake cooling oil Brake cooling oil strainer Pilot line filter element Air conditioner outer filter Replace Replace Change Replace Change Check Replace Change Replace Replace Replace 7 28 7 38 7 43 7 46 7 26 7 47 7 47 7 39 7 51 Check items Service Remarks Hydraulic tank suction strainer Radiator coolant Hydraulic oil 2 Crankcase breather filter Hoses fittings clamps fuel coolant hydraulic ...

Page 165: ...e and exhaust system Air cleaner element DEF level Hydraulic tank Hydraulic oil Hydraulic oil suction strainer Return oil filter element Air breather element Hand pump cabin tilt Hydraulic oil Tire air pressure Drain or Clean Check Drain Replace Change Replace Add Change Clean Replace Check Refill Add or Change Check Clean Replace Replace Add or Change Check Add 7 29 7 29 7 30 7 20 7 20 7 22 7 25 ...

Page 166: ...r drain plug to avoid injury by unexpected spouting of high temperature fluid or gas Open the cap slowly to relieve pressure Always keep the surface of control instrument panels clean in case of damage or malfunction detected in panel please it by a new one For other details refer to the service manual MAINTENANCE LOCATIONS MAINTENANCE LOCATIONS 1 1 5 MAINTENANCE CHART 5 MAINTENANCE CHART CAUTION ...

Page 167: ...cate G 1 Initial 100 Hours 1 Axle gear oil differential hub x 2 Change GO 19 5 0 3 6 Transmission oil Change EO 35 9 2 1 10 Brake cooling oil Change BO 27 7 1 1 18 Transmission oil filter Replace 1 250 Hours or monthly 1 Axle gear oil differential hub x 2 Check Add GO 19 5 0 3 10 Brake cooling oil Check Add BO 27 7 1 1 15 Lift chain Check Lubricate EO 2 16 Tilt pin Mast roller Check Lubricate G 2 ...

Page 168: ... injury and cause serious injury CABIN CABIN Be sure that the driver s cabin and any safety devices are in place undamaged and attached securely Check the cabin for damage Be sure that it is properly positioned and all mounting fasteners are in place and tight LOAD HANDLING COMPONENTS LOAD HANDLING COMPONENTS Inspect the mast assembly load backrest rails carriage rollers lift chains and lift and t...

Page 169: ... mm 24 in carpenter s square on the top of the block and against the shank Check the fork 500 mm 20 in above the metal block to make sure it is not bent more than 12 5 mm 0 5 in maximum If the fork blades are obviously bent or damaged have them inspected by a trained maintenance person before operating the truck Inspect the fork locking pins for cracks or damage Reinsert them and note whether they...

Page 170: ...ead of the tire not form the side Use a long handled gauge to keep your body away from handled gauge to keep your body away from the side If tires are low do not operate and the side If tires are low do not operate and do not add air Check with a mechanic The do not add air Check with a mechanic The tire may require removal and repair tire may require removal and repair Incorrect low tire pressure...

Page 171: ...gs can be easily performed It is recommended that the service requiring tilting cabin must be carefully performed with a skilled service man Tilting and returning cabin Tilting and returning cabin Refer to page 3 39 for the cabin tilt switch Refer to page 3 39 for the cabin tilt switch and hand pump lever and hand pump lever Tilting cabin Tilting cabin After keeping clearance of the people except ...

Page 172: ...MI64 160D9LMI66A Fill and check hydraulic oil for hand pump Open upper cap and fill 0 8 by using funnel After filling operate tilt cylinder 2 3 times and close the cabin completely to check the oil level in tank If necessary fill more oil to keep the level ÂTank capacity 0 7 ÂSystem total capacity 1 2 5 Do not operate cabin tilting function while the power is ON or engine is running Drain Reservoi...

Page 173: ...vel is in the normal range normal range Normal Dipstick L H Dipstick Oil drain plug Engine oil filter Clean around the filter head remove the filter by the filter wrench and clean the gasket surface The O ring can stick on the filter head Be The O ring can stick on the filter head Be sure it is removed before installing the new fil sure it is removed before installing the new fil ter ter 7 SERVICE...

Page 174: ...l to drain down before Allow 15 minutes for oil to drain down before checking checking Clean and check the lubricating oil drain plug threads and sealing surface Install the lubricating oil pan drain plug Tightening torque M18 6 1 kgf m 44 lbf ft M22 8 2 kgf m 59 lbf ft Fill the engine with clean oil to the proper level Quantity 14 2ℓ 3 7 U S gallons 2609A6MA07 160D7A6MA08 2609A6MA09 160D7A6MA10 5...

Page 175: ...If in doubt contact your local authorities for If in doubt contact your local authorities for guidance as to proper handling of used guidance as to proper handling of used antifreeze antifreeze 4 4 1 1 A B FULL LOW 2 1 CHECK COOLANT LEVEL CHECK COOLANT LEVEL Check the coolant level at reservoir tank when the engine is cooled Add the mixture of antifreeze and water after removing the cap of the res...

Page 176: ...r or a commercially available equivalent Use 0 5 kg 1 0 pound of sodium carbonate Use 0 5 kg 1 0 pound of sodium carbonate for every 23 liters 6 0 U S gallons of water for every 23 liters 6 0 U S gallons of water Do not install the surge tank cap The Do not install the surge tank cap The engine is to be operated without the cap for engine is to be operated without the cap for this process this pro...

Page 177: ...ill rate of 19 liters 5 0 U S gallons per minute Do not exceed this fill rate The system must be filled slowly to prevent The system must be filled slowly to prevent air locks air locks During filling air must be vented from the During filling air must be vented from the engine coolant passage engine coolant passage Cooling system filling Cooling system filling Use a mixture of 50 percent water an...

Page 178: ... opposite direction of the fan air flow Visually inspect the radiator for bent or broken fins If the radiator must be replaced due to bent If the radiator must be replaced due to bent or broken fins which can cause the engine to or broken fins which can cause the engine to overheat refer to the manufacturer s overheat refer to the manufacturer s replacement procedures replacement procedures Visual...

Page 179: ... Tighten the capscrews if necessary mounted Tighten the capscrews if necessary Replace any fan that is damaged Replace any fan that is damaged 8 8 FAN BELT FAN BELT 7 7 An deflection method can be used to check belt tension by applying 11 3 kgf 25 lbf force between the pulleys on V belts If the deflection is more than one belt thickness per foot of pulley center distance the belt tension must be a...

Page 180: ...t with the spring case stop is still in contact with the spring case stop the tensioner must be replace stop the tensioner must be replace Check the location of the drive belt on the belt tensioner pulley The belt should be centered on or close to the middle of the pulley Misaligned belts either too far forward or backward can cause belt wear belt roll offs or increase uneven tensioner bushing wea...

Page 181: ... tion of the filter is needed If there is any dam age to the filter body gaskets or endplates do not clean or reuse the filter should be discard ed Always clean filters in a clean environ ment observe strict inspection procedures and repackage filters immediately after the cleaning process with appropriate materials Use observe proper safety precautions and dispose of waste materials in an environ...

Page 182: ...urs Drain water Drain water Open bowl drain valve to evacuate water Close drain valve Don t tighten up a drain valve so strong Don t tighten up a drain valve so strong Please inspect and drain water frequently for Please inspect and drain water frequently for remain water volume to be less than 1 3 remain water volume to be less than 1 3 volume of a collection bowl volume of a collection bowl Bowl...

Page 183: ...tly in the center of Do not pour fuel directly in the center of the filter since this will allow unfiltered the filter since this will allow unfiltered fuel to enter the system and can cause fuel to enter the system and can cause damage to fuel system components damage to fuel system components Tighten the new cartridge until the gasket contacts the filter head surface and tighten it an additional...

Page 184: ...ines The fuel pump high pressure fuel lines and fuel rail contain very high pressure and fuel rail contain very high pressure fuel Do not loosen any fittings while fuel Do not loosen any fittings while the engine is running Personal injury the engine is running Personal injury and property damage can result Wait and property damage can result Wait at least 10 minutes after shutting down at least 1...

Page 185: ...the tank Before filling the tank Switch off the engine Secure the truck against rolling away Always fill the tank with at least 5 liters as smaller amounts could cause malfuctions Be careful to entering dust sand or other Be careful to entering dust sand or other contamination substance when you refill the contamination substance when you refill the DEF AdBlue into the tank Otherwise fatal DEF AdB...

Page 186: ... element are removed from the aftertreatment DEF are removed from the aftertreatment DEF dosing unit they must be discarded and dosing unit they must be discarded and replaced regardless of condition replaced regardless of condition 16 16 1 1 1 2 3 250D9DEF01 290F6MA60 1 DEF dosing unit filter cap 2 DEF filter equalizing element 3 DEF dosing unit filter element Clean and inspect for reuse Clean an...

Page 187: ... kgf m 14 5 lbf ft Lubrication of the DEF filter O rings is not Lubrication of the DEF filter O rings is not required required The aftertreament DEF dosing system will The aftertreament DEF dosing system will not prime until the correct SCR temperatures not prime until the correct SCR temperatures are reached To verify that there are no DEF are reached To verify that there are no DEF leaks test dr...

Page 188: ...the rocker lever cover Exposure to oil can cause the gasket to swell Exposure to oil can cause the gasket to swell which can make it difficult to install the which can make it difficult to install the gasket back into groove If the gasket comes gasket back into groove If the gasket comes out of the groove do not attemp to install the out of the groove do not attemp to install the gasket Replace it...

Page 189: ...must be fully seated around the entire perimeter of the rocker lever cover entire perimeter of the rocker lever cover groove groove 1 5 2 3 4 7609A6MI28 8 Apply clean engine oil to the O rings on the crankcase breather filter Install the filter onto the rocker lever cover 7609A6MI29 9 Install the crankcase breather filter cover Install the filter cover capscrews Tighten the capscrews starting with...

Page 190: ...ed lines Add hydraulic oil if necessary Add hydraulic oil if necessary Refer to the page 5 6 for details Refer to the page 5 6 for details 19 19 1 2 3 160D9LMI21 FILLING HYDRAULIC OIL FILLING HYDRAULIC OIL Stop the engine to the position of level check Check air breather element and replace it if necessary Loosen cap and fill the oil to the specified level Start engine after filling and operate th...

Page 191: ...n the oil air is entering the hydraulic system Inspect the suction hoses hydraulic system Inspect the suction hoses and hose clamps for leakage or damage and hose clamps for leakage or damage Drain pan Drain plug Cap Air breather 21 21 1 2 3 4 5 6 7 160D9LMI19 CLEAN SUCTION FILTER AND REPLACE CLEAN SUCTION FILTER AND REPLACE RETURN FILTER RETURN FILTER Clean and replace the return filter in the fo...

Page 192: ...9LMI18 OUT Frame RH side Line filter IN Element Valve Case O ring Line filter assy REPLACE OF PILOT LINE FILTER REPLACE OF PILOT LINE FILTER Loosen the filter case Pull out the filter element and clean the filter case Replace the filter element and O ring with new parts Reassemble the line filter 24 24 1 2 3 4 160D9LMI23 CLEANING BRAKE LINE FILTER CLEANING BRAKE LINE FILTER Remove the strainer fro...

Page 193: ...es for excessive heat and pressure of tire are insufficient pressure excessive load and overspeed Avoid excessive load and overspeed in order to keep tires in good shape Do not inflate tires using flammable gases or alcohol injector This cause explosion or personal injury Inflate tires at the pressure level recommended by the manufacturer and check periodically pressure and wear of tires When repl...

Page 194: ...n those Otherwise it may cause of permanent deformation Tread Valve Side wall Carcass Bead REPLACEMENT OF TIRE REPLACEMENT OF TIRE Disassembly reassembly replacement and Disassembly reassembly replacement and repair of tire requires special skills and repair of tire requires special skills and equipment Contact a tire repair shop equipment Contact a tire repair shop Tires to be replaced Tires to b...

Page 195: ...specified tighten torque Tightening torque 83 2 10 0 kgf m 602 72 3 lbf ft 1 2 3 4 5 6 7 8 9 10 4 4 STORING TIRES AFTER REMOVAL STORING TIRES AFTER REMOVAL As a basic rule store the tires in a warehouse which unauthorized persons cannot enter If the tire are stored outside always erect a fence around the tires and put up No Entry and other warning signs that even young children can understand Stan...

Page 196: ... lying in the zone HOT Insert the oil dipstick again and tighten it by clockwise rotation When checking put the parking brake switch When checking put the parking brake switch in the LOCK position and fix the tires with in the LOCK position and fix the tires with blocks blocks HOT COLD ZONE HOT Dipstick REPLACEMENT OF TRANSMISSION OIL REPLACEMENT OF TRANSMISSION OIL AND FILTER ELEMENT AND FILTER E...

Page 197: ...out 1 3 to 1 2 turn Mount the drain plug of the transmission after cleaning it Fill the oil through the dipstick inlet and check if the oil is at the appropriate level The proper oil amount is 16 liters 4 2 U S gallons As the truck is hot after operation wait until As the truck is hot after operation wait until the temperature has dropped the temperature has dropped It is imperative to pay attenti...

Page 198: ...ing oil Air breather CHECK AND SUPPLYING AXLE OIL CHECK AND SUPPLYING AXLE OIL Move the truck to flat ground Open the axle air breather to relieve internal air pressure Air breather Remove the plug and check the oil amount If the oil level is at the hole of the plug it is normal Oil fill level plug Differential gear 32 32 1 2 33 33 1 2 3 110D9MI45 160D9LMI46 160D9LMI47 ...

Page 199: ...ng put the filling plug of planetary gear in parallel to the ground Planetary gear Oil fill level plug Planetary gear Oil fill level plug 34 34 1 2 3 4 5 160D9LMI48 160D9LMI50 160D9LMI48 160D9LMI49 If the oil level is below the plug hole supply oil through a plug hole When checking the oil level engage the When checking the oil level engage the parking brake and fix the tires with blocks parking b...

Page 200: ...mal change replace it earlier than normal change interval interval Oil fill level plug Planetary gear Differential gear Oil fill level plug CLEANING AXLE BREATHER CLEANING AXLE BREATHER Remove dust or debris around the breather Remove the breather and wash it with a cleaning oil Air breather 6 7 35 35 1 2 160D9LMI52 160D9LMI46 BRAKE BRAKE COOLING OIL AND STRAINER COOLING OIL AND STRAINER Check the...

Page 201: ...After lubricating clean off spilled grease Put the parking brake switch in the LOCK Put the parking brake switch in the LOCK position and fix front and rear tires with position and fix front and rear tires with blocks blocks Set the mast and forks in a stable position Set the mast and forks in a stable position 1 2 37 37 Fork Fork retainer pin Carriage Bolt Fork retainer Cylinder retainer pin 160D...

Page 202: ...he rotating part of working device to extend the lubricating interval Mount the lip to be faced out side when Mount the lip to be faced out side when replace the dust seal replace the dust seal If it is assembled in wrong direction it will If it is assembled in wrong direction it will cause fast wear of pin and bushing and cause fast wear of pin and bushing and create noise and vibration during op...

Page 203: ...f the electronic control units MCU ECM TCU cluster etc Connect the earth ground lead of the welding equipment as close to the welding points as possible Do net weld or flame cut on pipes or tubes Do net weld or flame cut on pipes or tubes that contain flammable fluids Clean them that contain flammable fluids Clean them thoroughly with nonflammable solvent before thoroughly with nonflammable solven...

Page 204: ... 160D9LMI51 When using the air conditioner for a long time open the window once every one hour Be careful not to overcool the cab The cab is properly cooled if the operator feels cool when entering there from outside About 5 C lower than the outside temperature When cooling change air occasionally CHECK DURING SEASON CHECK DURING SEASON Ask the service center for replenishment of refrigerant or ot...

Page 205: ...warming Do not release refrigerant into the environment Safety precautions Work on the air conditioning system must only be performed by a qualified service technician Do not attempt to preform work on the air conditioning system Wear safety goggles chemical resistant gloves and appropriate personal protective equipment to protect bare skin when there is a risk of contact with refrigerant Action i...

Page 206: ...h the electrolyte Do not stain clothes or skin with the electrolyte as it is acid as it is acid Be careful not to get the electrolyte in the eyes Be careful not to get the electrolyte in the eyes Wash with clean water and go to the doctor if it Wash with clean water and go to the doctor if it enters the eyes enters the eyes 1 1 2 2 36070FW05 Recycle Recycle Never discard a battery Always return us...

Page 207: ...s and replace confirm the condition of the cables and replace it when the cables possess any kind of it when the cables possess any kind of abnormal damages such as cracking and wear abnormal damages such as cracking and wear out of the cable sheath that make you feel out of the cable sheath that make you feel somedangerous to use it Do consult an expert somedangerous to use it Do consult an exper...

Page 208: ...ck For wheels using a separate type rim check first that the rim nut separate type rim check first that the rim nut is not loose before loosening the lug nuts is not loose before loosening the lug nuts Be careful not to mistake the rim nuts and Be careful not to mistake the rim nuts and lug nuts lug nuts When assembling separated type rims with When assembling separated type rims with bolts and nu...

Page 209: ...the cover forward to remove it When replacing the fuse or relay check the relationship between the fuse or relay and the When replacing the fuse or relay check the relationship between the fuse or relay and the electrical components it protects Always replace fuses or relays with a same capacity electrical components it protects Always replace fuses or relays with a same capacity Always turn the s...

Page 210: ... repaired before the truck is put into operation Hour meter Hour meter Start the engine and let it warm up until it runs evenly and accelerates smoothly when you push on the accelerator pedal Check the hour meter for operation with the engine running Write the hour meter reading on the PM report form Report any malfunction or damage 1 1 2 2 6 6 Lamp Spec 24V Head lamp 70W Turn signal lamp LED Clea...

Page 211: ...ast as it lowers When the forks reach the floor release the lever All movements of the mast fork carriage and lift chains must be even and smooth without binding or jerking Watch for chain wobble or looseness the chains should have equal tension and move smoothly without noticeable wobble Auxiliary controls Auxiliary controls option If your lift truck is equipped with an attachment test the contro...

Page 212: ... Move the gear selector lever from NEUTRAL to FORWARD Remove your right foot from the service brake pedal and put it on the accelerator pedal Push down until the truck moves slowly forward Remove your foot from the accelerator pedal and push down on the service brake pedal to stop the truck The brakes should apply smoothly and equally Be sure the travel area is clear behind the truck Be sure the t...

Page 213: ...ng oil and grease Wipe up all oil spills Keep the controls and floorboards clean dry and safe A clean truck makes it easier to see leakage and loose missing or damaged parts and helps prevent fires A clean truck runs cooler The environment in which a lift truck operates determines how often and to what extent cleaning is necessary For example trucks operating in manufacturing plants that have a hi...

Page 214: ...with a set LH RH RH Do not piece chains together Do not piece chains together Lift chain inspection and measurement Lift chain inspection and measurement Inspect and lubricate the lift chains every 10 hours or daily and check tension every 250 hours or monthly When operating in corrosive environments inspect the chains every 50 hours During the inspection check for the following conditions Rust an...

Page 215: ...stance from the center of one pin to the center of the next pin All chains must be replaced if any link has wear of 3 or more or if any of the damaged conditions notes above are found during inspection Order replacement chains from your HYUNDAI dealer Replace all chains as a set Do not remove factory lubrication or paint new chains Replace anchor pins and worn or broken anchors when installing new...

Page 216: ...tely Run the engine at low idling Open the hood to ventilate the engine compartment When the water temperature drops stop the engine Check the cooling water level If it is low add more water Wear safety glasses and a face shield when using compressed air Never touch the radiator Wear safety glasses and a face shield when using compressed air Never touch the radiator cap while the engine is hot Ste...

Page 217: ...ily started the next morning When the electrolyte level is low add distilled water in the morning before work instead of When the electrolyte level is low add distilled water in the morning before work instead of after the day s work This is to prevent fluid from freezing at night after the day s work This is to prevent fluid from freezing at night CARE AFTER DAILY OPERATION CARE AFTER DAILY OPERA...

Page 218: ...Diesel Exhaust Fluid DEF compatible with AdBlue Description Specification Engine oil SAE 10W 30 15W 40 API CJ 4 class or better DEF AdBlue ISO 22241 32 5 high purity urea and 67 5 deionized water Transmission oil Engine oil SAE10W 30 API CF4 class or better Drive axle gear oil SAE 80W 90 Brake cooling oil Donax TD Hydraulic oil ISO VG46 VG68 Hyundai genuine long life hydraulic oil ISO VG15 Convent...

Page 219: ...SO VG 46 ISO VG 68 侏ASTM D975 NO 1 ASTM D975 NO 2 侏NLGI NO 1 NLGI NO 2 Ethylene glycol base permanent type 50 30 20 10 0 10 20 30 40 58 22 4 14 32 50 68 86 104 侏1 Ultra low sulfur diesel sulfur content 15 ppm 侏 Cold region Russia CIS Mongolia 侏2 Hydraulic oil capacity Refer to page 5 6 侏Ethyleneglycolbasepermanenttype 60 40 侏SAE 5W 40 SAE numbers given to engine oil should be selected according to...

Page 220: ...mm in 2450Ý250Ý100 100Ý9 8Ý3 9 Mast Tilt angle forward backward C C degree 10 10 15 10 opt Max height K mm ft in 4665 15 3 Min height M mm ft in 3200 10 6 Body Travel speed Unload km h 35 2 Gradeability Load degree 17 2 31 16 4 29 4 Min turning radius Outside E mm ft in 5220 18 1 ETC Operating pressure kgf cm2 230 Hydraulic oil tank U S gal 203 53 6 Fuel tank U S gal 276 72 9 Overall length A mm f...

Page 221: ... displacement cc cu in 6690 409 Compression ratio 17 3 1 Rated gross horse power ps rpm 165 8 2300 Maximum gross torque at rpm kgf m rpm 74 7 1500 Engine oil quantity ℓ U S gal 14 2 3 8 Dry weight kg lb 520 1146 High idling speed rpm 2230 50 Low idling speed rpm 700 1200 Rated fuel consumption g ps hr 168 Starting motor V kW DENSO 24 3 7 Alternator V A 24 70 Battery V AH 24 100 Item Unit Specifica...

Page 222: ...96 3 0 994 RR 1 5 647 2 2 404 3 0 997 Axle Type Front wheel drive type fixed location Gear ratio 12 7 1 Gear Ring pinion gear type Wheels Q ty FR RR Double 4 2 Front drive 12 00 20 20PR Rear steer 12 00 20 20PR Brakes Travel Front wheel Wet disk brake Parking Axle pinion caliper brake hydraulic released Steering Type Full hydraulic power steering Steering angle 71 9 to both right and left angle re...

Page 223: ...stem Transmission mounting bolt nut top M16Ý2 0 29 7Ü4 5 215Ü32 5 Transmission mounting bolt nut side M20Ý2 5 60 5Ü5 5 438Ü39 8 8 Torque converter mounting socket bolt M10Ý1 5 4 5Ü0 6 32 5Ü4 3 9 Drive axle mounting bolt nut M24Ý2 0 100Ü15 723Ü109 10 Steering axle mounting bolt nut M24Ý3 0 100Ü15 723Ü109 11 Front Rear wheel mounting nut M22Ý1 5 83 2Ü10 602Ü72 3 12 Propeller shaft mounting bolt nut ...

Page 224: ...lace with specified fuel Lack of fuel Air mixed in fuel system Fuel injection pump or nozzle defec tive Starting motor rotates slowly Engine compression insufficient Valve clearance out of adjustment Refill fuel Bleed air Replace See Electrical system Contact dealer Adjust clearance Thermostat faulty Water temperature gauge faulty Replace Replace Radiator fin clogged or fin damaged Thermostat or w...

Page 225: ...ure warning lamp does not light when enig ne is stopped with starting switch left in ON position Caution lamp defective Caution lamp switch defective Replace Replace Faulty wiring Glow plug damaged Check and repair Replace Faulty wiring Insufficient battery voltage Check and repair Recharge battery Insufficient battery voltage Starting motor defective Recharge battery Replace Insufficient battery ...

Page 226: ...free wheel malfunctioning Air sucked in Water intruding into transmission case Bearing worn or seizing Gauge malfunctioning Clutch dragging Bearing worn or seized Check oil level Add or drain oil as necessary After draining oil from oil tank and transmission check and replace interfering parts Check enigne stalling speed If necessary replace Check the inlet side joint or pipe If necessary retighte...

Page 227: ...l 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 wheel...

Page 228: ...r defects and replace Probable cause Remedy 5 Power is not transmitted 1 Torque converter 2 Transmission Clutch plate damaged Low oil level Oil pump driving system faulty Shaft broken Lack of oil pressure Low oil level Inching valve and link lever improper ly positioned Forward reverse spool and link lever improperly positioned Clutch fails to disengage 1 Clutch case piston ring defective 2 Main s...

Page 229: ...rack Disassemble and check for wear of seal lips and mating sliding surfaces pump boss coupling etc Replace oil seal pump boss coupl ing etc Check and retighten or replace pack ing Check and repair or replace gasket Check and retighten or gasket Check and replace cracked part Foreign matter intruding into oil pass age to clutch Shaft spline worn Disassemble check and repair or replace Disassemble ...

Page 230: ...t air bleeding Oil pump Oil inlet pipe sucks air Valve Faulty Unbalance oil pressure Piping Pipe from pump to power steering dented or clogged Insufficient air bleeding Flow control valve orifice clogged Piping Pipe from tank to pipe dented or clogged Retighten Replace Adjust Bleed air Adjust valve set pressure and check for specified oil pressure Repair or replace Add oil Repair Bleed air complet...

Page 231: ...d Wheel bearing out of adjustment Hydraulic system clogged Adjust tire pressure Adjust Repair by polishing or replace Adjust or replace Clean Repair and add oil Bleed air Replace Repair or replace Clean Probable cause Remedy 3 Brake trailing 4 Overheat Pedal has no play Piston cup faulty Brake valve return port clogged Hydraulic system clogged Wheel bearing out of adjustment Cooling oil insufficie...

Page 232: ... Oil leaks from joint or hose Excessive restriction of oil flow on pump suction side Relief valve fails to keep specified pressure Poor sealing inside cylinder High hydraulic oil viscosity Mast fails to move smoothly Oil leaks from lift control valve spool Oil leaks from tilt control valve spool Excessive restriction of oil flow pump suction side Gear or bearing in hydraulic pump defective Foreign...

Page 233: ...smoothly Deformed masts or carriage Faulty hydraulic equipment Damaged load and side rollers Unequal chain tension between LH RH sides LH RH mast inclination angles are unequal Mast assembly is twisted when tilted Disassembly repair or replace See Troubleshooting Hydraulic Cylinders pump and control valve in section 6 hydraulic system Replace Adjust chains Adjust tilt cylinder rods Abnormal noise ...

Page 234: ...easons such as overloading glancing blows against walls and objects and picking up load unevenly Difference in fork tip height If the measured value exceeds the allowance replace fork Fatigue Fatigue failure may result from the fatigue crack even though the stress to fork is below the static strength of the fork Therefore a daily inspection should be done Crack on the fork heel Crack on the fork w...

Page 235: ...00D9OM10 WHEN ACCELERATOR PEDAL IS DEPRESSED WHEN ACCELERATOR PEDAL IS DEPRESSED Check that accelerator pedal does not catch when depressed Check that engine speed increases in accordance with amount pedal is depressed When doing this check that engine speed changes without gasping abnormal noise abnormal explosions or irregular vibration Check that exhaust gas is colorless when the engine is idli...

Page 236: ...ICATION Always use HYUNDAI Forklift genuine parts when replacing the element After replacing the element run the engine and check for oil leakage from the filter mount 1 2 3 5 5 ENGINE OIL ENGINE OIL Check oil level with dipstick and add oil if necessary Check oil for discoloration or deterioration Change oil if discolored or deteriorated Engine oil quantity 14 2ℓ 3 8 U S gal 1 2 3 6 6 ENGINE OIL ...

Page 237: ...the belt tension must be adjusted Inspect the fan belt for damage Transverse across the belt cracks are acceptable Longitudinal direction of belt ribs cracks that intersect with transverse cracks are not acceptable Inspect the belt Embedded debris Uneven excessive rib wear Exposed belt cords Glazing high heat If any of the above conditions are present If any of the above conditions are present the...

Page 238: ...n reverse solenoid valve operates and oil comes to reverse clutch thus the truck will run backward OIL LEAKAGE 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 1 2 2 1 1 2 2 ADJUSTMENT OF PEDAL ADJUSTMENT OF PEDAL Accelerator pedal Accelerator pedal Pedal operating range is A If the range is differ...

Page 239: ...lt 1 so that pedal angle is H voltage 1 0 1V Pedal angle H 35 When fully pedaled voltage is controlled to 3 5 0 1V Adjust bolt 3 so that brake pedal interconnects with inching pedal at inching pedal stroke 22 mm 0 9 in 3 3 1 2 3 20 24 m m H 160D9LTA05 ...

Page 240: ...ICATIONS 2 2 RIM SIDE RING RIM SIDE RING Check rim side ring for deformation or cracks Check visually or use crack detection method Rear rim connecting nut torque SEE SECTION 8 SPECIFICATIONS 3 3 D35ATA15 STEERING AXLE STEERING AXLE Push axle in from one side or measure front to rear clearance with feeler gauge Check that clearance is within 2mm If clearance is more than 2mm insert shim to reduce ...

Page 241: ...nge should be 30 60 mm at rim of steering wheel If play is too large adjust at gearbox Test steering wheel play with engine at idling 30 60mm 1 2 2 4 in 1 1 2 2 STEERING AXLE STEERING AXLE Put camber gauge in contact with hub and measure camber If camber is not within 1 0 5 rear axle is bent Ask assistant to drive truck at minimum turning radius Fit bar and a piece of chalk at outside edge of coun...

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