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Hyundai 50DS-7E, User Manual

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Hyundai 50DS-7E User Manual Download Page 31

1-14

TIPOVER

TIPOVER

Seat belts can reduce injuries.

Seat belts can reduce injuries.
ALWAYS BUCKLE UP.

ALWAYS BUCKLE UP.

D35AOM31

B207OM10

Avoid these conditions.  They can cause a 
truck to tip over or lose traction for braking or 
driving.

Know  the  weight  of  your  truck  and  load.   

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

Summary of Contents for 50DS-7E

Page 1: ...rs 1 5 5 Pedestrians 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 overhe...

Page 2: ...ND OPERATING PROCEDURES 1 Before operating the truck 5 1 2 Check before starting 5 2 3 Check before starting engine 5 3 4 Seat adjustment 5 7 5 Starting from a safe condition 5 8 6 General starting and operating tips 5 9 7 Starting the engine 5 10 8 Check after starting engine 5 11 9 Levers and pedals 5 13 10 Operating safely 5 15 11 Load handling 5 17 12 Shut down procedure 5 23 6 EMERGENCY START...

Page 3: ...commendation table for lubricants 7 40 16 Fuel and lubricants 7 41 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 system 9 1 2 Electrical system 9 2 3 Torque flow system 9 3 4 Steering system 9 7 5 Brake system 9 8 6 Hydraulic system 9 10 10 TESTING AND ADJUSTING 10 TESTING AN...

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

Page 5: ...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 before...

Page 6: ... 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 is ...

Page 7: ...nd 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 for ...

Page 8: ...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 your supe...

Page 9: ...N 12053 are as followings The value of vibrations transmitted by the operator s seat are lower than standard value of 2005 88 EC 0 5 EC REGULATION APPROVED EC REGULATION APPROVED Model LWA EU only LPA 50DS 60DS 70DS 7E 107 dB 82 dB ...

Page 10: ...oise 22 Load chart 23 Label UL 24 Name plate CE 25 Name plate UL 26 Fuse 27 Fire extinguisher 28 Solid tire 29 Hanger 31 Accumulator 32 TPEM 1 LOCATION 1 LOCATION Always keep these labels clean If they are lost or damaged attach them again or replace them with new labels 3 13 12 16 20 1 26 5 START SWITCH 10 29 11 2 8 3 15 31 DASHBOARD COVER VIEW A A 18 14 17 25 24 32 21 DASHBOARD 6 FAN SHROUD 28 2...

Page 11: ... is In case of working under the forks it is essential to support the carriage with essential to support the carriage with blocks blocks 1 1 TEMPERATURE TEMPERATURE item 13 This warning label is positioned on the left of top side of sub bonnet Coolant must be checked as specified in Coolant must be checked as specified in the maintenance chart the maintenance chart 2 2 0 7 92SB 00250 053 053㶊 07 0...

Page 12: ...ear the front fender and the rear fender of the left side of the main frame It warns of the danger of injury from It warns of the danger of injury from movement between rails chains movement between rails chains sheaves fork carriage and other parts of sheaves fork carriage and other parts of the mast assembly Do not climb on or the mast assembly Do not climb on or reach into the mast Personal inj...

Page 13: ...g position to regain powered direction control Control of mast tilting lifting and lowering is not possible through operation of the appropriate control when the operator is not in the normal position Travel and mast OPSS only 8 8 92HA 00241 G This forklift equipped with an operator existence sensingsing system per ISO 3691 Please review Operator s manual for safe operation of forklift Power trave...

Page 14: ...x 5 6 ON position It needs approx 5 6 seconds to set correct position of throttle seconds to set correct position of throttle Warnings before leaving the operator seat Be sure to lower the attachment to the ground Apply the parking brake Cautions before starting or operating the truck Put the gear selector lever in the neutral Apply the brake Read this operator s manual carefully 10 10 1 2 0 10 92...

Page 15: ...at the operator have severe injury or death in the event of a tip over Outstretch the legs as widely as possible and grasp firmly the steering handle Learn the body to the opposite direction in order to avoid severe injury or death when the machine is tipped over Refer to page 3 4 for details Refer to page 3 4 for details 13 13 NOISE NOISE item 21 This warning plate is located on the front side of...

Page 16: ...enoid valve The accumulator is filled with high The accumulator is filled with high pressure nitrogen gas and i t i s extremely pressure nitrogen gas and i t i s extremely dangerous if it is handled in the wrong dangerous if it is handled in the wrong way Always observe the following way Always observe the following precautions precautions Never make any hole in the accumulator Never make any hole...

Page 17: ... NUMBER Inform following when you order parts or the machine is out of order MACHINE SERIAL NUMBER It s shown on front of the right side frame 1 D255SM02 Important safety hint It indicates matters which can cause the great loss on the machine or the surroundings It indicates the useful information for operator 3 SYMBOLS 3 SYMBOLS 0 13 1 DIRECTION 1 DIRECTION GUIDE GUIDE ...

Page 18: ...brication table Check for damage and maintenance problems Have repairs made before you operate the truck Do not make repairs yourself Lift truck mechanics are trained professionals They know how to make repairs safely 1 SAFETY HINTS 1 SAFETY HINTS 1 DAILY INSPECTION 1 DAILY INSPECTION D35AOM01 ...

Page 19: ... wear safety equipment when required D35AOM05 Don t mix drugs or alcohol with your job Don t block safety or emergency equipment D35AOM04 D35AOM02 Don t smoke in NO SMOKING areas or when refueling D35AOM06 2 DO S AND DON TS 2 DO S AND DON TS ...

Page 20: ...rs in rainy day Exclude the truck equipped cabin Exclude the truck equipped cabin D35AOM07 Exhaust gas is dangerous Do not operate the truck at the inhouse if possible Provide adequate ventilation when working in a closed space D35AOM08 ...

Page 21: ...s can reduce injuries Seat belts can reduce injuries B207OM10 Always buckle up for the machine Always buckle up for the machine equipped with safety belt equipped with safety belt D507OM09 3 SEAT BELTS 3 SEAT BELTS ...

Page 22: ...1 5 The operator is the only one who should be on a truck Never transport personnel on the forks of a lift truck 1 2 4 NO RIDERS 4 NO RIDERS D255OM11A D255OM12A ...

Page 23: ...oadway you do Sound your horn at all intersections or blind spots D35AOM13 Watch for people in your work area even if your truck has warning lights or alarms People may not watch for you D35AOM14 Watch for people standing back even when you are parked D35AOM15 1 2 3 5 PEDESTRIANS 5 PEDESTRIANS ...

Page 24: ...our body within the confines of the truck Do not operate truck without overhead Do not operate truck without overhead guard unless condition prevent use of a guard unless condition prevent use of a guard guard 1 2 6 OPERATOR PROTECTION 6 OPERATOR PROTECTION ...

Page 25: ...orks D255OM17A There is special equipment to raise people for overhead work DO NOT USE LIFT TRUCKS D255OM12A Always lower the load slowly Raise and lower with mast vertical or tilted slightly back Never forward D255OM01 7 FORK SAFETY 7 FORK SAFETY ...

Page 26: ...use the mast as a ladder Don t use the mast as a ladder D255OM62 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 D255OM63 8 PINCH POINTS 8 PINCH POINTS ...

Page 27: ...n D35AOM23 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 D255OM24A Unstable loads are a hazard to you and to your fellow workers Always make certain that the load is well stacked and evenly positioned across both forks Never attempt to lift a load with only one fork Wrong D255OM25A 1 2...

Page 28: ...M27A 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 10 GRADES RAMPS SLOPES AND INCLINES 10 GRADES RAMPS SLOPES AND INCLINES ...

Page 29: ...ongitudinal 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 dr...

Page 30: ... 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 31: ...ck 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 32: ...top before leaving truck Be sure travel control is in NEUTRAL D35AOM34 Lower forks fully to floor and tilt forward OFF ON S T A R T 2 1 D255OM35A Set parking brake Position 1 Lock Position 2 Release Turn key to OFF position 1 2 3 4 5 20D7OM24 13 PARKING 13 PARKING ...

Page 33: ...ng oil check around machine for oil leakage D255OM02 Keep away from fire when adding oil or during operation DIESEL D255OM03 After adding oil wipe off any oil spilled on machine D255OM04 14 REFUELING 14 REFUELING 1 2 3 ...

Page 34: ...1 17 When getting on or off the machine use the step provided D255OM05 Do not jump up or down from the machine D255OM06 15 STEP 15 STEP 1 2 ...

Page 35: ...elt is Always buckle up if a seat belt is provided provided D35AOM23 Parking brake must be locked in the PARK POSITION before exiting from the vehicle Parking brake must remain locked in the Parking brake must remain locked in the park position 2 except when an operator park position 2 except when an operator is in the normal operating position is in the normal operating position HYUNDAI 2 Lock Pa...

Page 36: ...ically reduce the stability of machine and may cause over turning Avoid overloading or uneven loading Avoid overloading or uneven loading Load on forks according to load capacity mentioned on machine name plate when sideshift is applied Uneven loading will deteriorate the stability of machine when load is raised Top of load should not extend above Top of load should not extend above backrest backr...

Page 37: ... Never carry loose or uneven material D255OM39 Center wide loads D35AOM40 Stack and band loose material D35AOM41 Avoid sudden braking or starting When the machine is loaded do not When the machine is loaded do not drive at maximum speed drive at maximum speed D255OM07 2 OPERATING HAZARDS 2 OPERATING HAZARDS 1 LOOSE LOADS 1 LOOSE LOADS ...

Page 38: ...g 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 2 LONG AND WIDE LOADS 2 LONG AND WIDE LOADS D35AOM42 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 p...

Page 39: ...n tip a Moving into overhead structures can tip a truck over or spill a load truck over or spill a load B207OM45 Slow down before turning Slow down before turning The truck can tip over The truck can tip over D255OM46 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 on...

Page 40: ...g with When right angle stacking or moving with a raised load to clear low objects avoid a raised load to clear low objects avoid sharp turns and move slowly sharp turns and move slowly 6 RIGHT ANGLE STACKING 6 RIGHT ANGLE STACKING D35AOM50 ...

Page 41: ...event chains from being slack 7 CHAIN SLACK 7 CHAIN SLACK D35AOM51 D35AOM52 Do not move or store materials on Do not move or store materials on damaged pallets or skids Items can fall damaged pallets or skids Items can fall through them causing severe injury or through them causing severe injury or death death Be sure the pallet or skid you are using Be sure the pallet or skid you are using is in ...

Page 42: ...55SF02 If the machine touches the electric power If the machine touches the electric power lines keep sitting on the operator s seat lines keep sitting on the operator s seat and make sure the personnel on the and make sure the personnel on the ground not to touch the machine until ground not to touch the machine until turning off the electric current turning off the electric current Jump off the ...

Page 43: ...ersons to stand or Never permit any persons to stand or pass under lifted load pass under lifted load 10 LIFTING LOADS 10 LIFTING LOADS D255OM08 D255OM09 Never use wire rope to lift a load Never use wire rope to lift a load ...

Page 44: ...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 35D7EOM64 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 l...

Page 45: ...he fork positioner with a load or with the fork arm on the ground Never move the levers to operate the fork positioner suddenly and quickly It can be caused to drop the load 35D7EOM65 12 FORK POSITIONER 12 FORK POSITIONER ...

Page 46: ... 3 Lift cylinder 4 Backrest 5 Tilt cylinder 6 Lift bracket 7 Forks 8 Overhead guard 9 Turn signal lamp 10 Head lamp 11 Operator s seat 12 Bonnet 13 Counterweight 14 Rear wheel 15 Front wheel 16 Rear combination lamp 50DS7EOM54 3 KNOW YOUR TRUCK 1 GENERAL LOCATIONS ...

Page 47: ... maximum load capacity of this truck with relation to load centers and fork heights See diagram on plate Personal injury and damage to the truck can occur if these capacities are exceeded Do not exceed the maximum capacity specified Truck weight The approximate weight of the truck without a load on the forks This weight plus the weight of the load must be considered when operating on elevators ele...

Page 48: ...he truck attachment combination and truck capacity with 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...

Page 49: ... decal is located on the front right hand leg of the drivers overhead Its purpose is to remind the operator that staying in the seat provides the best chance of avoiding injury in the event of a truck tipping or driving off a dock mishap Lift trucks can be tipped over if operated improperly Experience with lift truck accidents has shown that the driver cannot react quickly enough to jump clear of ...

Page 50: ...eaner element warning lamp 9 Head lamp signal lamp 10 Right turn signal lamp 11 Fuel gauge 13 Parking brake signal lamp 14 Hour meter 15 Preheater signal lamp 16 Water separator lamp 17 T M display 18 T M temperature gauge 19 Seat belt warning lamp 20 Parking brake lever 21 Gear selector lever 22 Head lamp switch 23 Clearance lamp switch 24 Turn signal switch 25 Horn button 26 Lift lever 27 Tilt l...

Page 51: ... immediately and move the truck to a safe place Open the engine hood to improve the ventilation and run the engine at low idling until the temperature drops to the white range For details see HANDLING MACHINE IN EXTREMELY HOT PLACES page 7 35 WATER TEMPERATURE GAUGE 3 1 2 3 ö ö 1 ö 2 15D7EOM02K 1 Η Θ Η Θ 2 ö This range indicates the temperature of transmission oil ÂWhite range 40 107 C 104 225 F Â...

Page 52: ...p shows that the alternator is not generating electricity When the starting switch is turned ON the lamp will lights up but it should go out after the engine starts If the lamp lights up during operation stop the engine and check the fan belt tension and the electrical system BATTERY CHARGE WARNING LAMP 1 ö ö 8 This lamp lights up when key is turned to ON position After a while the heater signal l...

Page 53: ...Head lamp goes out Signal lamp goes out HEAD LAMP SIGNAL LAMP 1 10 Η Θ 77073CD12 3 8 Right turn signal lamp flickers when pulling on the turn signal lever RIGHT TURN SIGNAL LAMP 1 12 D35AOM88 This lamp shows that the parking brake is applied or not Parking brake locked Signal lamp lights up Parking brake unlocked Signal lamp goes out Make sure that the signal lamp goes out before operating the mac...

Page 54: ...ter is over the normal temperature 104 C 219 C Check the cooling system when the lamp is ON 1 2 ENGINE OVERHEAT WARNING LAMP 18 15D7E3CD17 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 fo...

Page 55: ...RANSMISSION ERROR DISPLAY Function The display can be used with the gear selector DW 3 It indicates speed and driving direction as well as the activated kickdown When driving in the automatic mode a bar indicator gives additionally also information 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...

Page 56: ... Select neutral to get fault code displayed WT Warning torque converter temperature Changes between actual gear direction while driving in neutral only displayed if no fault is detected spanner WS Warning sump temperature Changes between actual gear direction while driving in neutral only displayed if no fault is detected spanner WE Warning high engine speed Changes between actual gear direction w...

Page 57: ...hex 34 hex 35 hex 36 hex 37 hex 38 hex 39 hex Meaning of error code Logical error at gear range signal Logical error at direction select signal Short circuit to battery voltage at clutch cutoff input Short circuit to ground or open circuit at clutch cutoff input Short circuit to battery voltage or open circuit at temperature sensor input Short circuit to ground at temperature sensor input Short ci...

Page 58: ...ery voltage at clutch KE Short circuit to ground at clutch KE Open circuit at clutch KE Short circuit to battery voltage at clutch KV Short circuit to ground at clutch KV Open circuit at clutch KV Short circuit to battery voltage at clutch KR Short circuit to ground at clutch KR Open circuit at clutch KR Short circuit to ground at relay reverse warning alarm Short circuit to battery voltage at rel...

Page 59: ...rt circuit to battery voltage at power supply for sensors Short circuit to ground at power supply for sensors Low voltage at battery High voltage at battery Error at valve power supply 1 Error at valve power supply 2 Communication failure on devicenet General EEPROM fault Configuration lost Application error ...

Page 60: ...le just opposite until the notch being aligned to ú When clearance lamp light up then the clearance lamp and all panel lamps light up too CLEARANCE LAMP SWITCH 1 2 ö 2 Head lamp lights up Twist the handle beneath steering wheel and make the notch align to Small lamp goes out Twist the handle just the opposite direction described as above HEAD LAMP SWITCH 1 2 3 35DS7EOM92 35DS7EOM91 Key must be in ...

Page 61: ...r the autoshift function changing from 1st to 3rd gear shift mode Automatic 2nd mode Ι Press the bottom of the switch fully for the autoshift function changing from 2nd to 3rd gear shift mode A A M A A M 1 2 FULL AUTOMATIC SWITCH 1 2 3 D507CD60 Η Θ Ι 7 This switch is used to shut off the entire electrical system When the machine is not operated for a long time turn OFF the master switch for the sa...

Page 62: ...pedal The inching pedal is used for fine control of forward and reverse movement when lifting up or putting down loads Do not put your foot on the inching pedal or brake pedal unless using it This lever is used for gear selection forward 3 stage and reverse 3 stage If turning the gear selector lever forward the machine increases the speed but if turning it backward the machine reduces the speed PE...

Page 63: ... Tilt backward Tilt forward D507OM18 Lift PULL the lever back to lift the load Lower PUSH the lever forward to lower the load Holding When the lever is released the lifting or lowering action stops Lifting speed is controlled by accelerator pedal Lowering speed is controlled by lever only LIFT LEVER 1 2 3 ö 14 Lift Lower D507OM17 LH movement Push the lever forward to move the left hand for the sid...

Page 64: ...forward to move outward for the LH fork Pull the lever backward to move inward for the LH fork RH fork movement Push the lever forward to move outward for the RH fork Pull the lever backward to move inward for the RH fork 刮 刯 刮 刯 LEVER FOR SIDE SHIFT WITH FORK POSITIONER OPTION 17 Pucker up Outstrech Inward Outward Inward Outward 60DF7CD19 60DF7CD21 60DF7CD22 Fork positioner synchronizer type Fork...

Page 65: ...G WHEEL ANGLE Turn the lock lever down Move the steering wheel forward or backward to select the most suitable position Turn lever up to lock the steering wheel in the desired position After adjusting try to move the steering wheel backward and forward to check that it is locked in the selected position Always carry out the adjustment with the machine stopped Never try to adjust the steering wheel...

Page 66: ...ot 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 truck and take note of obvious damage that may have been caused by operation during the last shift Check that all ...

Page 67: ...heck the Gauges meters and indicator lights Service brakes inching pedal and parking brakes Hydraulic controls lift tilt and auxiliary If installed Accelerator Gear selector lever Steering system Lift mechanism and any attachments When the functional check are completed follow the standard shutdown procedures given in Section 5 Starting and operating procedures Starting and operating procedures CO...

Page 68: ...and fuel 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 50 or 100 hours of Replace following after initial 50 or 100 hours of operation operation 4 4 Avoid excessive operation for initial 100...

Page 69: ...tance while refueling safe distance while refueling 80D7OM106 D35AOM106 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 immediately Wipe off the spilt fuel oil immediately USE CLEAN PROPERLY MARKED FUEL C...

Page 70: ...t 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 a DRIVER S OVERHEAD GUARD unless Protect yourself Do not operate truck without a DRIVER S ...

Page 71: ...fety and to realize maximum service life for your machine The numbers on the inspection chart show the order of inspection These numbers correspond to the check item numbers given on the following pages Hang a caution sign on the truck for example Do not start Do not start or Maintenance in progress Maintenance in progress This will prevent anyone from starting or moving the truck by mistake 2 D35...

Page 72: ...ode causing serious injury or damage The tires and rims should always be serviced or changed by trained personnel 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 using the correct tools and procedures For details of procedures contact your HYUNDAI dealer or tire repair shop dea...

Page 73: ...efore adding water Always allow the radiator to cool down before adding water At the operating temperature the engine cooling water is at high temperature and pressure At the operating temperature the engine cooling water is at high temperature and pressure so it is dangerous to try to open the radiator cap Wait until the radiator is cool enough to be so it is dangerous to try to open the radiator...

Page 74: ...ries Do not stain clothes or skin with electrolyte as it Do not stain clothes or skin with electrolyte as it is acid is acid Be careful not to get the electrolyte in eyes Be careful not to get the electrolyte in 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 Make sure to keep the batteries fully charged at Make...

Page 75: ...on and lamp switch if operate normally or not 2 Horn button 2 Lamp switch If horn and lamp are malfunctioning contact your HYUNDAI forklift distributor 1 2 50DF7OM13 If the operating force is below 20 30 kg 44 66 lb contact your HYUNDAI forklift distributor CHECK PARKING BRAKE CHECK PARKING BRAKE 10 10 1 Operating force 20 30 kg 44 66 lb 2 2 Check for any catching or abnormal heaviness when depres...

Page 76: ... the seat belt at least once every three years Replace the seat belt at least once every three years regardless of appearance regardless of appearance 1 L255OM119 Forward Backward adjustment A Forward Backward adjustment A Pull lever A to adjust seat forward or back ward The seat can be moved forward and backward over 156 mm in 12 steps Reclining adjustment B Reclining adjustment B Pull lever B to...

Page 77: ...unction All controls are in neutral or other correct position The truck has received its daily inspection and ready and safe to operate 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 Forks are down Parking brake is set D255OM31 Neutral Forward Reverse D155OM123 5 STARTING FROM A SA...

Page 78: ...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 79: ...r explosive substances that could cause serious injury Starting fluid is especially dangerous explosive substances that could cause serious injury Starting fluid is especially dangerous when used on engines with glow plugs Never use starting fluid with a glow plug equipped when used on engines with glow plugs Never use starting fluid with a glow plug equipped engine engine Turn the start switch to...

Page 80: ...e fuel system can be caused a difficulty The moisture in the fuel system can be caused a difficulty of the engine starting and may lead to a serious problem for of the engine starting and may lead to a serious problem for the engine function the engine function Do not smoke or allow any flame near the truck when Do not smoke or allow any flame near the truck when refilling Refilling produces explo...

Page 81: ...abnormal heaviness in steering CHECK REARVIEW MIRROR CHECK REARVIEW MIRROR Option Adjust the rearview mirror for best rearward visibility 7 7 8 8 D255OM35 CHECK MONITOR CHECK MONITOR 4 4 If the steering wheel play is over 30 60 mm 1 2 2 4 in check or repair it CHECK STEERING WHEEL PLAY CHECK STEERING WHEEL PLAY 5 5 30 60mm 1 2 2 4 in D35AOM127 FUEL LEVEL WARNING LAMP ENGINE OIL PRESSURE WARNING LA...

Page 82: ...h 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 attachment Also improper operation faulty maintenance or poor housekeeping may contribute to a condition of instability housekeeping may cont...

Page 83: ...RAKING PEDAL BRAKING PEDAL 4 4 INCHING PEDAL INCHING PEDAL 5 5 D35AOM131 D35AOM132 D35AOM133 Use the inching pedal and the accelerator pedal in combination to vary lift and travel speeds independently The further you depress the inching pedal the more the driving clutch slips reducing travel motion With the inching pedal fully depressed the brakes fully engage You operate the inching pedal with yo...

Page 84: ...t be considered a substitute for good judgement and care in loading handling storage etc 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 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 c...

Page 85: ...letely familiar with all the safe driving and load handling techniques in this Operator s Manual Use common sense Drive carefully do not indulge in stunt driving or horseplay Observe traffic rules Watch for people and hazards Slow down be in full control of your lift truck at all times Follow the instructions in this manual to avoid damage to your truck or the possibility of injury to yourself of ...

Page 86: ...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 87: ...BR or fork retaining bolts are Make sure the load backrest LBR or fork retaining bolts are fasten securely in place fasten securely in place 2 2 D35AOM134 LOAD ON FORKS LOAD ON FORKS Do not elevate the load with one forks Do not elevate the load with one forks Loading with one fork can cause the tip over and serious injury or death of operator This can cause the height difference between both fork...

Page 88: ...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 89: ...r 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 ...

Page 90: ...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 91: ...eral inches then set the load down and move forward until the front face of the forks contacts the load Be careful that the fork tips now clear the adjacent load or material behind the load being moved Raise the load from the stack by tilting the mast back just enough to lift the load from the surface Or with the mast still vertical raise the forks until they begin to lift the load At this point a...

Page 92: ...he parking brake Lower the lifting mechanism carriage and forks or attachment fully to the ground 1 1 2 2 1 2 3 1 2 3 4 Forks are down Parking brake is set D255OM31 IN ADDITION WHEN LEAVING THE IN ADDITION WHEN LEAVING THE TRUCK UNATTENDED TRUCK UNATTENDED Tilt the mast forward until the forks are level and flat on the ground Let the engine run at idle speed Turn the starting switch to the OFF pos...

Page 93: ...sabled 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 available Replace it when necessary only with a genuine HYUNDAI replacement part...

Page 94: ...can move and 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 starting switch to the OFF position Engage the parking brake Remove the key and when necessary block the wheels to prevent the truck from rolling 9 ...

Page 95: ...icator looks illuminated or has a bright color Install a new battery BATTERIES EMIT EXPLOSIVE GAS Do not smoke or have open flames or sparks in 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...

Page 96: ...hat move Do not touch hot manifolds that can cause sever burns Start the engine on the Jumper vehicle Jumper vehicle and run the engine at a moderate speed for a minimum of five minutes Start the engine on the Stalled vehicle Stalled vehicle Follow the starting instructions in section 5 Starting and Operating Procedures Starting and Operating Procedures in this manual Be sure that the engine is at...

Page 97: ...recommends that the owner set up and follow a periodic planned maintenance PM and inspection program Performed on a regular basis by trained personnel the program provides through truck The PM PM identifies needed adjustments repairs or replacements so they can be made before failure occurs The specific schedule frequency for the PM inspections depends on the particular application and lift truck ...

Page 98: ...nts 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 flammable cleaning fluids for cleaning parts Befor...

Page 99: ...age 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 necessary ...

Page 100: ...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 101: ...als are intended 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 hou...

Page 102: ...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 completion of service For more deta...

Page 103: ...hose Replace clamp at the same time if the hose clamp is cracked when checking and replacing Replace clamp at the same time if the hose clamp is cracked when checking and replacing hose hose No Periodical replacement of safety parts Interval 1 Fuel hose Every 2 to 4 years 2 Hydraulic pump hose Every 2 years 3 Power steering hose Every 2 years 4 Packing seal and O ring for steering cylinder Every 2...

Page 104: ... wheel 7 Drive axle 8 Propeller shaft 9 Hydraulic pump 10 Priority valve 11 Transmission 12 Torque converter 13 Engine 14 Exhaust pipe 15 Steering axle 16 Steering cylinder 17 Rear wheel 18 Radiator 19 Muffler 20 Silencer 21 Air cleaner 22 Overhead guard 23 Seat 24 Steering wheel 25 Control lever 26 Steering unit 26 1 2 3 4 5 21 22 23 24 25 6 7 20 8 9 10 11 12 13 14 15 16 17 18 19 50DS7EOM21 ...

Page 105: ...orn and lamp Gauges and instrument panel Warning light Service brake and inching operation Parking brake operation Accelerator and engine speed operation Directional and speed control operation Steering wheel operation Noise and vibration Service Remarks EVERY 50 HOURS SERVICE EVERY 50 HOURS SERVICE 2 2 Check items 7 18 7 19 7 20 7 27 8 4 8 4 8 4 8 4 8 4 8 4 8 4 8 4 8 4 8 4 8 4 Check Clean Change ...

Page 106: ...end Attachment option cylinder rod end Attachment option cylinder tube end Steering axle wheel bearing Pedal pivot Service Remarks EVERY 500 HOURS SERVICE EVERY 500 HOURS SERVICE 5 5 Check items Air cleaner element change interval may be determined by using an air restriction indicator Diesel fuel filter change interval may be determined by fuel filter restriction indicator In case of the hard ope...

Page 107: ...ent Hydraulic tank Hydraulic oil Hydraulic oil suction strainer Return oil filter element Air breather filter Tire air pressure Service Remarks 5 12 5 6 7 19 7 19 7 19 7 28 7 22 7 18 7 21 7 21 7 30 7 30 5 3 EVERY 2000 HOURS SERVICE EVERY 2000 HOURS SERVICE 7 7 Check items Clean Change Change Hyd suction strainer Radiator coolant Hydraulic oil 1 Service Remarks 7 21 7 22 7 21 EVERY 5000 HOURS SERVI...

Page 108: ...meter reading Stop the engine when servicing Do not open the cap or drain plug to avoid injury by unexpected spouting of high temperature fluid or gas Open the cap slowly to relieve pressure Always keep the surface of control instrument panels clean in case of damage or malfunction detected in panel replace it with a new one For other details refer to the service manual ...

Page 109: ...lic pump drive Check Add G 1 13 Steering axle linkage Check Add G 1 17 Transmission oil level Check Add MO 18 1 Initial 50 Hours 8 Engine oil Change EO 16 5 1 9 Engine oil filter Replace 1 Initial 100 Hours 14 Differential gear oil Change GO 12 5 1 17 Transmission oil Change MO 18 1 18 Transmission oil filter Replace 1 250 Hours or monthly 1 Tilt pin mast roller Check Lubricate G 2 2 Lift chain Ch...

Page 110: ...e serious injury OVERHEAD GUARD OVERHEAD GUARD Be sure that the driver s overhead guard and any safety devices are in place undamaged and attached securely Check the overhead guard for damage Be sure that it is properly positioned and all mounting fasteners are in place and tight LOAD HANDLING COMPONENTS LOAD HANDLING COMPONENTS Inspect the mast assembly load backrest rails carriage rollers lift c...

Page 111: ...rk with the 100 mm 4 in surface against the blade Put a 600 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 blade to make sure it is not bent more than 25 mm 1 in maximum If the fork blades are obviously bent or If the fork blades are obviously bent or damaged have them inspected by a trained damaged have them inspected by a trained m...

Page 112: ...read of the tire not form the side Use a long handled gauge to keep your body away long handled gauge to keep your body away from the side If tires are low do not operate from the side If tires are low do not operate and do not add air Check with a mechanic and do not add air Check with a mechanic The tire may require removal and repair The tire may require removal and repair Incorrect low tire pr...

Page 113: ...s 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 used batteries to one of the following locations A battery supplier An authorized bat...

Page 114: ...ion given with the cleaner Have a spare element ready so that the machine can start working again immediately 2 2 20DFOM26 D35AOM158 3 3 Keep clean condition for the air cleaner element all the times Keep clean condition for the air cleaner element all the times A dirty air cleaner could be decreased output power of the engine at worst and it also will be A dirty air cleaner could be decreased out...

Page 115: ...eplace the fuel filler when the engine is cool Carry out this maintenance in a place away from fire Removing the fuel filler will produce explosive fumes Wipe off any spilled fuel or from fire Removing the fuel filler will produce explosive fumes Wipe off any spilled fuel or oil immediately from the truck or surrounding area oil immediately from the truck or surrounding area Using a filter wrench ...

Page 116: ...roved eye protection rated for 200 kPa 30 psi is required for air cleaning 200 kPa 30 psi is required for air cleaning operation operation Blow dry compressed air from the inside of strainer to outside and install when completely dry Dispose of used oil in locally approved manner DIFFERENTIAL CASE DIFFERENTIAL CASE Differential oil Differential oil Park the truck in a level place Set the mast vert...

Page 117: ...200 kPa 30 psi is required for air cleaning OSHA approved eye protection rated for 200 kPa 30 psi is required for air cleaning operation operation When changing oil remove strainer and clean it with flushing oil Blow dry compressed air from inside of strainer to outside and install when completely dry Dispose of oil in locally approved manner Bleed the air after checking the oil level as below Sta...

Page 118: ... Then stop the engine and drain water Close drain valves and fill radiator with clean water Do not pour cold water in an overheated Do not pour cold water in an overheated engine It can be caused the crack of the engine It can be caused the crack of the engine block due to sudden cooling engine block due to sudden cooling For low temperatures add antifreeze See For low temperatures add antifreeze ...

Page 119: ...the jack does not come out of carefully that the jack does not come out of position When jacking up the truck never position When jacking up the truck never go under the truck For wheels using a go under the truck 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 ...

Page 120: ... the cover forward to remove it When replacing the fuse check the relationship between the fuse and the electrical When replacing the fuse check the relationship between the fuse and the electrical components it protects Always replace fuses with a fuse of the same capacity Always turn components it protects Always replace fuses with a fuse of the same capacity Always turn the starting switch OFF ...

Page 121: ...ing components be sure they are properly mounted and working correctly Horn Horn Press the horn button to check horn function If the horn or any other part does not operate report the failure and have it 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...

Page 122: ...qual tension and move smoothly without noticeable wobble Auxiliary controls Auxiliary controls Option If your lift truck is equipped with an attachment test the control lever for correct function and briefly operate the attachment Service brakes and inching pedal Service brakes and inching pedal With the gear selector lever in NEUTRAL and the engine running push the service brake pedal fully down ...

Page 123: ...elease the service brake and push down on the accelerator pedal until the truck moves slowly in the reverse direction Remove your foot from the accelerator pedal and push down on the service brake pedal to stop the truck The brakes should apply smoothly and equally Put the gear selector lever in FORWARD Press the inching pedal fully down and hold Depress the accelerator The truck should not move N...

Page 124: ...flow hose for logging or damage Engine cooling system Engine cooling system To check engine coolant level open the hood to the engine compartment Visually inspect the recovery bottle locate the MAX and MIN marks The MAX mark indicates maximum level at operating temperature The MIN mark indicates additional coolant needs to be added to the system 7 28 Engine air cleaner Engine air cleaner Check the...

Page 125: ...ty For diesel engines HYUNDAI recommends that you use motor oil that meets API CH4 and SAE 10W 30 Hydraulic sump tank Hydraulic sump tank Check the hydraulic sump tank fluid level Correct fluid level is important for proper system operation Low fluid level can cause pump damage Over filling can cause loss of fluid or lift system malfunction Hydraulic fluid expands as its temperature rises Therefor...

Page 126: ...ocation of grease fittings Inspect the steering cylinder piston rods seals and fasteners for damage leaks and looseness Lubricate the steering axle linkage rod ends and linkage pivot points Be sure to clean the grease fittings before lubricating and remove the excess grease from all points after lubricating Lubricate miscellaneous linkage as needed Mast and tilt cylinder lubrication Mast and tilt ...

Page 127: ...e Chains need periodic maintenance to give maximum service life Do not attempt to repair a worn chain Replace worn or damaged chains with a set LH and Do not attempt to repair a worn chain Replace worn or damaged chains with a set LH and RH Do not piece chains together RH Do not piece chains together 15 15 16 16 AIR CLEANING AIR CLEANING Always maintain a lift truck in a clean condition Do not all...

Page 128: ...chain measurement and maintenance and maintenance 3 3 1 2 3 4 D255OM15 1 Lift chain inspection and measurement Lift chain inspection and measurement Inspect and lubricate the lift chains every PM 250 hours When operating in corrosive environments inspect the chains every 50 hours During the inspection check for the following conditions Rust and corrosion cracked plates raised or turned pins tight ...

Page 129: ...hange oil or add oil Figures in squares indicate number of lubricating points All service intervals in the chart are based on daily 2 weeks 1 month 3 months 6 months 12 months 30 months and service meter readings Mark Kind of lubricants In moderate weather Cold region 1 EO Engine oil API CH4 class or better MO T M oil ATF DEXRON III 50DS 7E 0021 70DS 7E 0192 SHELL DONAX TD 50DS 7E 0022 60DS 7E 000...

Page 130: ...7 34 9 GREASING POINT 9 GREASING POINT Lift chain coated with engine oil Steering axle Tilt cylinder Fork stopper Adjust bolt Mast support Pedal pin 50DS7EOM173 ...

Page 131: ...d 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 Steam may spurt out Wait until the water temperature drops It cap while the engine is hot Steam may spurt out Wait until the water temperature drops It is extremely dangerous to try to check the fan belt tension whil...

Page 132: ...e can be readily 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 AFTE...

Page 133: ... started run it at idling speed until it is warmed up completely BEFORE STORAGE When you keep your forklift truck in storage for an extended period of time observe the following safeguard instruction Wash and tidy the truck and house it in a dry building When the truck has to be placed outdoors park it on a even ground and cover it securely with canvas Give enough fuel grease lubricant and oil Coa...

Page 134: ... 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 machine are aligned The loading ramps should be of sufficient width length and thickness to permit safe loading or unloading After checking that the machi...

Page 135: ...Do not load abruptly Keep area clear of personnel Keep area clear of personnel 14 LOADING AND UNLOADING BY CRANE 14 LOADING AND UNLOADING BY CRANE 1 2 3 4 5 Do not install the wire to unsafe position such Do not install the wire to unsafe position such as forks carriage head guard counterweight as forks carriage head guard counterweight lifting hole or towing pin etc It can cause lifting hole or t...

Page 136: ...ng and Material Description Specification Engine oil SAE 10W 30 API CH4 class or better T M oil ATF DEXRON III 50DS 7E 0021 70DS 7E 0192 SHELL DONAX TD 50DS 7E 0022 60DS 7E 0001 70DS 7E 0193 Gear oil SAE 80W 90 API GL 5 DRY MOBILFLUID 424 WET Hydraulic oil ISO VG46 VG68 Hyundai genuine long life hydraulic oil ISO VG15 Conventional hydraulic oil 1 Brake oil DOT3 DRY AZOLLA ZS32 Hydraulic oil ISO VG...

Page 137: ... type 50 50 50 30 20 10 0 10 20 30 40 58 22 4 14 32 50 68 86 104 Cold region Russia CIS Mongolia Ethyleneglycolbasepermanenttype 60 40 SAE 5W 40 SAE numbers given to engine oil should be selected according to ambient temperature For engine oil used in engine oil pan use SAE 10W oil when the temperature at the time of engine start up is below 0 C even if the ambient temperature in daytime is expect...

Page 138: ...g speed Unload Load mm sec 450 500 L W T L W T mm 1200 150 60 1200 150 65 Mast Tilt angle forward backward C C degree 15 10 Max height D mm 4275 Min height E mm 2500 Body Travel speed Unload km h 35 5 35 4 35 2 Gradeability degree 24 8 46 2 22 1 40 7 20 0 36 5 Min turning radius Outside F mm 3270 3315 3360 ETC Operating pressure kgf cm2 185 Hydraulic oil tank ℓ 105 Fuel tank ℓ 150 Overall length G...

Page 139: ...u in 4996 305 Compression ratio 22 Rated gross horse power ps rpm 92 2300 Maximum gross torque at rpm kgf m rpm 29 9 1700 Engine oil quantity ℓ U S gal 16 5 4 3 Dry weight kg lb 360 792 High idling speed rpm 2570 Low idling speed rpm 820 Rated fuel consumption g ps hr 180 Starting motor V kW 24 5 0 Alternator V A 24 50 Battery V AH 12 96 2 Fan belt deflection mm in 10 12 0 4 0 5 Item Unit Specific...

Page 140: ... type Overhaul ratio FWD 1st 4 446 2nd 2 341 3rd 0 974 REV 1st 4 443 2nd 2 340 3rd 0 973 Axle Type Front wheel drive type fixed location Gear ratio 10 545 Wheels Q ty FR RR Double 4 2 Front drive 8 25 15 14 PR Rear steer 8 25 15 14 PR Brakes Travel Front wheel Duo servo dry wet disk brake wet Parking Toggle internal expanding mechanical type Steering Type Full hydraulic power steering Steering ang...

Page 141: ...rain system Transmission mounting bolt nut M16 2 0 7 5 54 6 Torque converter mounting bolt M10 1 5 6 9 1 4 50 10 7 Drive axle mounting bolt nut M24 3 0 100 15 723 108 8 Steering axle mounting bolt nut M18 2 5 41 3 6 2 300 45 9 Front wheel mounting nut M22 1 5 61 2 9 2 448 67 10 Rear wheel mounting nut M22 1 5 61 2 9 2 448 67 11 Others Counterweight mounting bolt M30 3 5 120 15 1555 239 12 Operator...

Page 142: ...t 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 Add fuel Repair Replace See Electrical system Repair Adjust clearance Thermostat faulty Water temperature gauge fault...

Page 143: ...gine 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 voltage Recharge battery Faulty wiring I...

Page 144: ...ree 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 engine stalling speed If necessary replace Check the inlet side joint or pipe If necessary retighten...

Page 145: ...nd add oil Check joints and pipes If necessary retighten joint or repla ce packing Check and replace Check oil pressure If necessary rep lace pump Check spring tension If necessary replace Disassemble check and repair or re place Disassemble check measure and re place Check stalling speed Increased engine load will cause ex cessive drop of stalling speed Check oil temperature rise If any replace f...

Page 146: ...efects and replace Probable cause Remedy 5 Power is not transmitted 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...

Page 147: ...ug Oil leaks from a crack 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...

Page 148: ...mp 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 Retighten Bleed air Adjust valve set pressure and check for specified oil pressure Repair or replace Add oil Repair Bleed air completely Repair ...

Page 149: ...eplace Adjust or replace Clean Repair and add oil Bleed air Clean or replace Repair by polishing or replace Replace Repair or replace Clean Probable cause Probable cause Remedy Remedy 3 Brake trailing 4 Brake chirps 5 Brake squeaks Pedal has no play Brake shoe poorly sliding Wheel cylinder mal functioning Piston cup faulty Return spring fatigued or bent Parking brake fails to return or out of adju...

Page 150: ... or replace Repair or replace Probable cause Probable cause Remedy Remedy 7 Large pedal stroke 8 Pedal dragging Brake out of adjustment Hydraulic line sucking air Oil leaks from hydraulic line or lack of oil Lining worn Shoe tilting or does not return compl etely Lining in poor contact with brake drum Twisted push rod caused by improp erly fitted brake valve Brake valve seal faulty Flow control va...

Page 151: ...ith air 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 ...

Page 152: ...ater signal lamp goes out turn key to START and start engine When engine starts check if it starts smoothly and if it makes any abnormal noise Refer to page 3 10 Refer to page 3 10 1 2 3 4 1 2 3 4 1 1 2 2 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 peda...

Page 153: ...the exhaust emission and black smoke BATTERY BATTERY Check electrolyte color Adding and charging distilled water of battery shall be performed by the following table of battery indicator 1 2 4 4 5 5 D35AOM158 35DF7OM08 Battery indicator COOLANT COOLANT Check coolant level If the cooling water in the radiator sub tank is not within the normal range add water to the MAX line If antifreeze is being u...

Page 154: ...cing the element After replacing the element run the engine and check for oil leakage from the filter mount 1 2 3 8 8 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 SEE 8 SPECIFICATION 1 2 3 9 9 ENGINE OIL FILTER ENGINE OIL FILTER The condition of the oil filter e...

Page 155: ...r pressure at a point midway between fan pulley and alternator pulley If fan belt tension is not correct loosen alternator mounting nut and bolt of adjustment bar Move alternator to adjust belt tension Keep the fan belt free from oil and Keep the fan belt free from oil and grease so that it can prevent the fan grease so that it can prevent the fan belt from slippage belt from slippage 1 2 3 4 A Dr...

Page 156: ...EAKAGE 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 Depress the accelerator pedal until Depress the accelerator pedal until reaching high idle rpm of the engine in reaching high idle rpm of the engine in o...

Page 157: ...ig h t Pedal stroke D155ATA05 Unit mm A Inching spool T M control valve Installed length of inching spool 20DFTA06 Embossed letter Inner cap Cap Brake fluid reservoir 35 75mm 1 4 3 0in 20DFTA14 CHECK OIL LEVEL CHECK OIL LEVEL Stop the machine in a flat place and check the oil level with the dipstick Brake reservoir Brake reservoir Check the brake reservoir and add brake fluid if necessary The embo...

Page 158: ...uch as personal injury due accidents such as personal injury due to slippage on the oil or fire to slippage on the oil or fire If the oil is spilt on the floor wipe it off If the oil is spilt on the floor wipe it off immediately immediately 2 2 TORQUE FLOW Transmission TORQUE FLOW Transmission Check the oil level with the oil gauge below the floor plate If the oil level is too low add oil through ...

Page 159: ...EE 8 SPECIFICATION 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 8 SPECIFICATION 3 3 D35ATA15 STEERING AXLE STEERING AXLE Push axle from one side or measure front to rear clearance with feeler gauge Check that clearance is within 2 mm If clearance is more than 2mm insert shim to reduce c...

Page 160: ...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 5 rear axle is bent Ask assistant to drive machine at minimum turning radius Fit bar and a piece of chalk at outside edge of coun...

Page 161: ...may be operated The stroke of the parking lever is as follows Specification 97 7 When the parking lever is located to When the parking lever is located to unlock position it should be adjusted the unlock position it should be adjusted the parking switch in order that the sensor of parking switch in order that the sensor of the switch may not touch with the the switch may not touch with the counter...

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