Hyundai 160D-9L Manual
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Hyundai 160D-9L Manual

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FOREWORD
FOREWORD
A message to hyundai lift truck operators ----------------------------------------------------------------------- 0-1
Introduction ------------------------------------------------------------------------------------------------------------------------ 0-2
How to use this manual ---------------------------------------------------------------------------------------------------- 0-3
EC regulation approved ----------------------------------------------------------------------------------------------------- 0-5
Safety labels ---------------------------------------------------------------------------------------------------------------------- 0-6
Guide (Direction, Serial number, Symbols) -------------------------------------------------------------------- 0-16
1. Daily inspection ------------------------------------------------------------------------------------------------------------- 1-1
2. Do's and don'ts -------------------------------------------------------------------------------------------------------------- 1-2
3. Seat belts ----------------------------------------------------------------------------------------------------------------------- 1-4
4. No riders ------------------------------------------------------------------------------------------------------------------------- 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
1. Loose loads -------------------------------------------------------------------------------------------------------------------- 2-1
2. Long and wide loads ----------------------------------------------------------------------------------------------------- 2-2
3. Rear swing --------------------------------------------------------------------------------------------------------------------- 2-2
4. Low overhead clearance ----------------------------------------------------------------------------------------------- 2-3
5. Fast turns and high loads ---------------------------------------------------------------------------------------------- 2-3
6. Right angle stacking ------------------------------------------------------------------------------------------------------ 2-4
7. Chain slack --------------------------------------------------------------------------------------------------------------------- 2-4
8. Pallets and skids ------------------------------------------------------------------------------------------------------------ 2-5
9. Caution for electrical lines --------------------------------------------------------------------------------------------- 2-5
CONTENTS
CONTENTS

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Summary of Contents for Hyundai 160D-9L

  • Page 1: Table Of Contents

    CONTENTS CONTENTS FOREWORD FOREWORD A message to hyundai lift truck operators ----------------------------------------------------------------------- 0-1 Introduction ------------------------------------------------------------------------------------------------------------------------ 0-2 How to use this manual ---------------------------------------------------------------------------------------------------- 0-3 EC regulation approved ----------------------------------------------------------------------------------------------------- 0-5 Safety labels ---------------------------------------------------------------------------------------------------------------------- 0-6 Guide (Direction, Serial number, Symbols) -------------------------------------------------------------------- 0-16 1. SAFETY HINTS 1.
  • Page 2 10. Lifting loads -------------------------------------------------------------------------------------------------------------------- 2-6 11. Side shift ------------------------------------------------------------------------------------------------------------------------- 2-7 12. Fork positioner --------------------------------------------------------------------------------------------------------------- 2-8 3. KNOW YOUR TRUCK 3. KNOW YOUR TRUCK 1. General locations ----------------------------------------------------------------------------------------------------------- 3-1 2. Name plate and safety warning decal ------------------------------------------------------------------------- 3-2 3. Cab devices ------------------------------------------------------------------------------------------------------------------- 3-4 4.
  • Page 3 6. EMERGENCY STARTING AND TOWING 6. EMERGENCY STARTING AND TOWING 1. How to tow a disabled truck ------------------------------------------------------------------------------------------ 6-1 2. Parking brake release ---------------------------------------------------------------------------------------------------- 6-3 3. How to use battery jumper cables -------------------------------------------------------------------------------- 6-4 7. PLANNED MAINTENANCE AND LUBRICATION 7. PLANNED MAINTENANCE AND LUBRICATION 1.

  • Page 4: A Message To Hyundai Lift Truck Operators

    HYUNDAI lift trucks are built to take hard work, but not abuse. They are built to be dependable, but they are only as safe and efficient as the operator and the persons responsible for maintaining them. Do not make any repairs to this truck unless you have been trained in safe lift truck repair procedures and are authorized by your employer.

  • Page 5: Introduction

    HYUNDAI lift truck in a safe and correct manner. Your HYUNDAI lift truck has been designed and built to be as safe and efficient as today's technology can make it. As manufactured, for some models, it meets all the applicable mandatory requirements of ANSI B56.1-1988 Safety Standard for Powered Industrial Trucks.

  • Page 6: How To Use This Manual

    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 information on possible updates or revisions.
  • Page 7 Acquaint yourself with the various procedures in this manual. Understand how all gauges, indicator lights, and controls function. Please contact your authorized HYUNDAI dealer for the answers to any questions you may have about your lift truck's features, operation, or manuals.

  • Page 8: Ec Regulation Approved

    EC REGULATION APPROVED Noise level (2000/14/EC and EN 12053) are as followings. Model (EU only) 160D-9L, 180D-9B 104 dB 71.2 dB The value of vibrations transmitted by the operator's seat are lower than standard value of (2005/88/EC)

  • Page 9: Safety Labels

    VIEW A CONSOLE BOX VIEW E 36 37 38 39 RCV LEVER CABIN INSIDE-RH CABIN INSIDE-LH 160D9LOM101 Logo (HYUNDAI) 19 Engine wash 36 Side shift Mast warning 20 Tire pressure 37 Fork clamp Hand caution 21 Brake cooling oil 38 Fork positioner...
  • Page 10 2. DESCRIPTION 2. DESCRIPTION There are several specific warning labels on this machine please become familiarized with all warning labels. Replace any safety label that is damaged, or missing. MAST WARNING MAST WARNING (ltem 3) This warning label is positioned on the left and right side of the mast.
  • Page 11 RADIATOR FAN RADIATOR FAN (Item 6) This warning label is positioned on the top side of cooling fan shroud. It warns of the danger or injury from It warns of the danger or injury from spinning fan blades when the engine is spinning fan blades when the engine is running.
  • Page 12 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. START WARNING START WARNING (Item 13) This warning label is positioned on the middle top side of dashboard cover.
  • Page 13 SAFETY INSTRUCTION SAFETY INSTRUCTION (Item 30) Truck for equipped with travel OPSS. This warning label is positioned on the left window of cabin inside if the truck is for SAFETY INSTRUCTIONS equipped with *OPSS. This forklift equipped with an operator existence sensing system per ANSI/ASME B56.1-7.21.10 and 7.21.11.
  • Page 14 OPERATOR SAFETY OPERATOR SAFETY (Item 12) This warning label is positioned on the left stay of cabin inside Refer to operator's manual in detail. Always buckle up the seat belt for safety operation. When the operator get off the truck, always turn the parking brake switch in LOCK position so that the truck can keep with stopping condition.
  • Page 15 TILT CABIN WARNING TILT CABIN WARNING (Item 17) This warning label is positioned on the left side of frame. Refer to page 7-18 for safe tilting Refer to page 7-18 for safe tilting procedure. procedure. 50D7EFW04 NOISE LEVEL NOISE LEVEL (Item 22) This warning label is located on the right side of the engine hood.
  • Page 16 A special air bleed valve is accumulator. A special air bleed valve is necessary for this operation, so please necessary for this operation, so please contact your Hyundai distributor. contact your Hyundai distributor. 0-13...
  • Page 17 DEF (UREA) DEF (UREA) (Item 15) This label is positioned on the inside side of the right side cover. UREA UREA ※ Fill the DEF / AdBlue® only. Fill the DEF / AdBlue® only. ※ Never use diesel oil. Never use diesel oil. (Diesel Exhaust Fluid) (Diesel Exhaust Fluid) 92HS-00122...
  • Page 18 BRAKE COOLING OIL BRAKE COOLING OIL (Item 21) This label is positioned on the right side of the frame. ※ Fill only the DOANX TD only. Fill only the DOANX TD only. BRAKE COOLING OIL BRAKE COOLING OIL ※ Never use others oil. Never use others oil.

  • Page 19: Guide (Direction, Serial Number, Symbols)

    GUIDE GUIDE 1. DIRECTION 1. DIRECTION The directions of this truck indicate forward, Front backward, right and left when truck is in the travelling direction. Left Right Rear 160D9LSM01 2. SERIAL NUMBER 2. SERIAL NUMBER Inform following when you order parts or the truck is out of order. 1) 1) TRUCK SERIAL NUMBER TRUCK SERIAL NUMBER...

  • Page 20: Safety Hints

    1. SAFETY HINTS 1. SAFETY HINTS 1. DAILY INSPECTION 1. DAILY INSPECTION At the beginning of each shift, inspect your truck and fill out a check, maintenance and lubrication table. Check for damage and maintenance problems. Have repairs made before you operate the truck. Do not make repairs yourself.

  • Page 21: Do's And Don'ts

    2. DO'S AND DON'TS 2. DO'S AND DON'TS Do watch for pedestrians. D35AOM03 Do wear safety equipment when required. D35AOM05 Don't mix drugs or alcohol with your job. D35AOM02 Don't block safety or emergency equipment. 160D9LOM04 Don't smoke in NO SMOKING areas or when refueling. D35AOM06...
  • Page 22 Don't operate the truck outdoors 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: Seat Belts

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

  • Page 24: No Riders

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

  • Page 25: Pedestrians

    5. PEDESTRIANS 5. PEDESTRIANS Watch where you are going. Look in the direction of travel. Pedestrians may use the same roadway 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.

  • Page 26: Operator Protection

    6. OPERATOR PROTECTION 6. OPERATOR PROTECTION 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.

  • Page 27: Fork Safety

    7. FORK SAFETY 7. FORK SAFETY Never allow anyone to walk under raised forks. 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).

  • Page 28: Pinch Points

    8. PINCH POINTS 8. PINCH POINTS Keep hands, feet and legs out of the Keep hands, feet and legs out of the mast. mast. D255OM61 Don't use 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.

  • Page 29: Travel

    9. TRAVEL 9. TRAVEL Travel with the load near the floor/ground, with mast tilted back to cradle the load whenever possible. Never lift or lower the load when the Never lift or lower the load when the truck is in motion. truck is in motion.

  • Page 30: Grades, Ramps, Slopes And Inclines

    10. GRADES, RAMPS, SLOPES AND INCLINES 10. GRADES, RAMPS, SLOPES AND INCLINES Never turn on a grade, either loaded or unloaded. Never turn on a grade, either loaded or unloaded. Unloaded-Forks downgrade 160D9LOM30 Loaded - Forks upgrade 160D9LOM33 1-11...

  • Page 31: Tip Over

    11. TIP OVER 11. TIP OVER 1) 1) LATERAL TIP OVER LATERAL TIP OVER L a t e r a l t i p o v e r c a n o c c u r w i t h a combination of speed and sharpness of turn.
  • Page 32 3) 3) WHAT TO DO IN CASE OF A TIP OVER WHAT TO DO IN CASE OF A TIP OVER If your truck starts to tip over, do not If your truck starts to tip over, do not jump. jump. Brace yourself as illustrated right.

  • Page 33: Surface And Capacity

    12. SURFACE AND CAPACITY 12. SURFACE AND CAPACITY 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...

  • Page 34: Parking

    13. PARKING 13. PARKING Never park on a grade. 160D9LOM41 Always come to a complete stop before leaving the truck. Be sure the travel control is in NEUTRAL. 160D9LOM42 Lower forks fully to the floor and tilt forward. 160D9LOM44 Put the parking brake switch in LOCK position.

  • Page 35: Refueling

    14. REFUELING 14. REFUELING Before adding fuel, check around truck for oil leakage. 160D9LOM47 Keep away from fire when adding fuel or during operation. 110D9OM48 After adding fuel, wipe off any fuel spilled on the truck. 160D9LOM49 1-16...

  • Page 36: Step

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

  • Page 37: Operator's Safety Rules

    16. OPERATOR'S SAFETY RULES 16. OPERATOR'S SAFETY RULES All operational functions require that the operator be seated in the operator's seat. Always buckle up if a seat belt is Always buckle up if a seat belt is provided. provided. 160D9LOM18 The parking brake must be locked in the LOCK POSITION before exiting from the truck.

  • Page 38: Side Shift

    17. SIDE SHIFT SIDE SHIFT Do not put side loads on the forks. Do not put side loads on the forks. 160D9LSS01 Restrict the sideshift movement with Restrict the sideshift movement with raised load. raised load. Abrupt sideshifting under such condition will dramatically reduce the stability of truck and may cause over-turning.

  • Page 39: Operating Hazards

    2. OPERATING HAZARDS 2. OPERATING HAZARDS 1. LOOSE LOADS 1. LOOSE LOADS L o o s e o r u n b a l a n c e d l o a d s a r e L o o s e o r u n b a l a n c e d l o a d s a r e dangerous.

  • Page 40: Long And Wide Loads

    2. LONG AND WIDE LOADS 2. LONG AND WIDE LOADS With long or wide loads, you need more With long or wide loads, you need more room. So slow down and watch your room. So slow down and watch your clearance.

  • Page 41: Low Overhead Clearance

    4. LOW OVERHEAD CLEARANCE 4. LOW OVERHEAD CLEARANCE Know the height of your truck, with and Know the height of your truck, with and without a load. Check your clearances. without a load. Check your clearances. Keep the load low and tilted back. Keep the load low and tilted back.

  • Page 42: Right Angle Stacking

    6. RIGHT ANGLE STACKING 6. RIGHT ANGLE STACKING When right angle stacking or moving 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.

  • Page 43: Pallets And Skids

    8. PALLETS AND SKIDS 8. PALLETS AND SKIDS 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.

  • Page 44: Lifting Loads

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

  • Page 45: Side Shift

    11. SIDE SHIFT 11. SIDE SHIFT 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 load. In case of moving the side shift with load, it can be caused load dropping or overturning of the forklift due to unbalanced weight.

  • Page 46: Fork Positioner

    12. FORK POSITIONER 12. FORK POSITIONER Do not operate the fork positioner with a load, or with the fork arm on 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.

  • Page 47: Know Your Truck

    3. KNOW YOUR TRUCK 1. GENERAL LOCATIONS 160D9LOM54 Mast Front wheel 15 Counterweight Lift chain Head lamp-fender 16 Rear combination lamp Lift cylinder 10 Tilt cylinder 17 Silencer Operator's seat 11 Work lamp-mast 18 Air conditioner (opt) Fork positioner cylinder 12 Rear view mirror 19 Rear work lamp Carriage...

  • Page 48: Name Plate And Safety Warning Decal

    Truck serial number An identification number assigned to this particular truck and should be used when requesting information or ordering service parts for this truck from your authorized HYUNDAI dealer. The serial number is also stamped on the frame. Attachment description (If any installed) The user must see that the truck is marked to identify the attachment (s), including the weight of the truck/attachment combination and truck capacity with the attachment.
  • Page 49 OPERATOR SAFETY WARNING DECAL 160D9LOM59 Safety and warning decals are placed in conspicuous locations on the truck to remind you of essential procedures or to prevent you from making an error that could damage the truck or possibly cause personal injury. You should know, understand, and follow these instructions.

  • Page 50: Cab Devices

    3. CAB DEVICES 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. Remote control lever type Front Rear...
  • Page 51 Fingertip type Front Rear Cluster Radio and USB player Multi function switch Steering wheel Fingertip Gear selector lever Starting switch Inching pedal Switch board Aircon & heater switch (opt) Cigar lighter Handsfree (opt) Remote controller (opt) Brake pedal Accelerator pedal Operator seat 160D9LCD01-1...

  • Page 52: Cluster

    4. CLUSTER STRUCTURE The cluster consists of gauges, lamps, buttons and LCD as shown below, to warn the operator in case of abnormal truck operation or conditions for the appropriate operation and inspection. Gauges : Indicate operating status of the truck. Warning lamps : Indicate abnormality of the truck.
  • Page 53 GAUGE Speed meter The speed meter displays the speed of truck in mph and km/h. - 0~50 km/h - 0~31 mph 50D93CD03K Fuel gauge This gauge indicates the amount of fuel in the fuel tank. Fill the fuel when the warning lamp lights ON or the indicator moves E point, refuel as soon as possible to avoid running out of fuel.
  • Page 54 WARNING LAMPS DEF low level warning lamp Transmission oil temp warning lamp Engine coolant temp warning lamp Engine check warning lamp Fuel low level warning lamp Battery charge warning lamp Seat belt warning lamp Fan error warning lamp Air cleaner warning lamp Transmission error warning lamp Brake oil temp warning lamp Brake oil pressure warning lamp...
  • Page 55 Engine oil pressure warning lamp This lamp comes ON for a while after starting the engine because of the low oil pressure. If the lamp comes ON during engine operation, shut OFF engine immediately. Check oil level. 50D93CD18 Air cleaner warning lamp This lamp operates by the vacuum caused inside when the filter of air cleaner is clogged.
  • Page 56 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. 50D93CD19...
  • Page 57 50% derate, 30 min. Engine error code 3712 DEF level final derate warning Flash Contact Hyundai service center or dealer. Manual SCR cleaning method 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.
  • Page 58 Engine stop warning lamp 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. 50D9CD33 (16) Fan error warning lamp This lamp is turned ON when the cooling fan error occurs.
  • Page 59 PILOT LAMPS DEF level pilot lamp Left turning pilot lamp Right turning pilot lamp Parking brake pilot lamp Head light pilot lamp Expendables replacement pilot lamp Inching pilot lamp Fuel warmer pilot lamp Preheater pilot lamp HEST pilot lamp SCR cleaning inhibit pilot lamp OPSS pilot lamp Cooling fan reverse pilot lamp 300D9CD02-2...
  • Page 60 Head light pilot lamp This lamp comes ON when the main light switch is operated to 2nd step. 50D9CD07 Preheater pilot lamp This lamp lights ON when start switch is turned clockwise to the ON position. Light will turn off after approximately 15~45 seconds, depending on engine coolant temperature, indicating that preheating is completed.
  • Page 61 SCR cleaning inhibit pilot lamp 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 temperature. Refer to the page 3-42 for the SCR cleaning switch.
  • Page 62 CLUSTER BUTTON Each button has the following function. Menu button Camera/Enter button Move button Buzzer stop/ESC button 160D9LCD121 Buzzer stop/ESC button This button is used to stop the buzzer sound. If another alarm condition occurs after this button has been pressed, the alarm buzzer will re-sound.
  • Page 63 Main screen You can select or set the menu by the button of the cluster. Please refer to the page 3-16 for the selection and change of the menu and input value. Main screen Main menu screen Sub menu screen MENU 180D9CD10 50D9CD11...
  • Page 64 Main menu Main menu Sub menu Description Model select Model select Tilt setting Tilt setting (mast and vehicle angle) Rear angle setting Rear angle setting Weight sensor setting Cross-section, load weight adjust, weight display setting, load indicator buzzer ESL setting ESL setting Vehicle max speed limit Vehicle max speed limit (10~30 km)
  • Page 65 Equipment Choose the equipment 180D9CD20 50D9CD21 To enter the menu, you must input user password. Default password is ‘00000’ You should set password by fi ve to ten digit. Model select 180D9CD22 300D9CD12 50D9CD23 Select the Model Turn the lift truck ON after turn it OFF when changing D-9 to D-9H or D-9H to D-9.
  • Page 66 Tilt setting 180D9CD26 50D9CD27 180D9CD28 Set the offset about mast angle sensors and vehicle angle sensors. Setting for rear wheel angle 180D9CD29 180D9CD30-1 180D9CD31 180D9CD34-1 180D9CD33 180D9CD32 The user revises a forklift truck steering angle. Display set to approve a condition. Right set rear wheel calibration.
  • Page 67 Weight sensor setting Cross-section 180D9CD35-1 180D9CD36-1 180D9CD37 Enter the designated cross-section (cm Mast spec 160D-9L V-Mast 226.19 VS-Mast 226.19 TS-Mast 265.46 180D9CD38 Load weight adjust Unloaded status adjustment In the unloaded from the ground waiting 5 seconds after lift 30 cm, and tare ON.
  • Page 68 180D9CD35-1 50D9CD39-1 50D9CD49 Initialization It is initialized loaded status and unloaded status. 50D9CD51-1 50D9CD50-1 Weight display setting 180D9CD35-1 50D9CD53-1 50D9CD54 Select the number of points of weight value display. 50D9CD55 Overload warning buzzer 180D9CD35-1 50D9CD57-1 50D9CD58-1 Choose using buzzer when over weight. 3-22...
  • Page 69 ESL setting 180D9CD59 50D9CD60 180D9CD61K 180D9CD55 50D9CD61-2 50D9CD61-3 180D9CD55 50D9CD62 50D9CD63 180D9CD55 50D9CD64-1 Set ON/OFF function for using limitation of ignition and time for starting. Set time 5 minutes for starting : In 5 minutes you can restart without password, but after 5 minutes, you should input password for starting. 3-23...
  • Page 70 Vehicle max speed limit 180D9CD65-1 50D9CD66-1 50D9CD67 Set the maximum speed. 10 km/h~30 km/h (1 km/h intervals) 50D9CD68 180D9CD69 50D9CD70-1 AEB setting 180D9CD71-1 180D9CD72 Press OK button, then calibration will be started, for cancel, press Menu/ECS/Enter button. When it is fi nished (OK sign at gear box), Press Menu/ECS/Enter button. Start the engine : AEB start Start switch ON : Brake pedal sensor calibration (R) MCU / Cluster information...
  • Page 71 Cooling fan reverse mode 180D9CD101-1 180D9CD103-1 Manual : The fan only rotate in reverse direction while you hold down the manual button. Automatic : The fan rotate in reverse direction at pre-set interval. - Interval : 30 minutes ~ 5 hours - Time : 30 seconds ~ 5 minutes Refer to the page 3-43 for the cooling fan control switch.
  • Page 72 Finger tip setting Lever position setting 50D9CD74 50D9CD74 50D9CD74 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.
  • Page 73 Lever deadzone setting 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 Ability to prevent the Value output due to a tiny error of the 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)
  • Page 74 Valve setting 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 Current Setting : Current setting for input each Valve Coil, it is to set up each maximum value 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.
  • Page 75 Maintenance Choose the maintenance 180D9CD75-1 180D9CD76 To enter the Menu, you must input user password. Default password is ‘00000’ You should set password by fi ve to ten digit. Failure history a. Current failure history 180D9CD77 180D9CD77-1 300D9CD78 Show the failure status of the current engine, transmission and/or air conditioner.
  • Page 76 c. Delete logged fault 180D9CD77 180D9CD77-3 300D9CD307 Initialize of the past logged fault history. Air conditioner : Option DCU : D-9H Only 180D9CD79-1 Maintenance management 180D9CD81 180D9CD82 180D9CD83 Exchange expendable supplies. Change the replacement cycle. Show the Maintenance 180D9CD84 180D9CD85 Information below 10.
  • Page 77 Signal status 180D9CD89-1 50D9CD90 180D9CD91 Display information of each sensors. 50D9CD92 180D9CD93 User password change 180D9CD94-1 50D9CD95-1 50D9CD96-1 You should set password by fi ve to ten digit. 180D9CD97 50D9CD97-1 3-28...
  • Page 78 Opening of communication 180D9CD98-1 180D9CD99 180D9CD100 When successfully opened RMCU communication, except for the RMCU comm. 180D9CD102-1 180D9CD101 180D9CD102 180D9CD104-1 180D9CD105-1 180D9CD107 180D9CD106 3-29...
  • Page 79 Display setting Choose the display setting No password is required. 180D9CD108 LCD adjustment 180D9CD109 50D9CD110 180D9CD111 50D9CD112 180D9CD113 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.) 180D9CD114 180D9CD115...
  • Page 80 Unit setting 180D9CD118 50D9CD118-1 50D9CD119 Change units of temperature / speed / wight / pressure. Language setting 180D9CD120 180D9CD121 180D9CD122 Set the language used by your device. (13 Multiple language) 50D9CD123 A/S phone number 50D9CD124 50D9CD125 180D9CD126 Check and change of contact information for customer service. ESL password change 50D9CD127 180D9CD128...
  • Page 81 Maintenance management 50D9CD131 50D9CD132-1 50D9CD133-1 Show the maintenance information (replacement cycle, elapsed time, change count, alarm information). 3-32...
  • Page 82 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. Transmission message display 180D93ACD33 If it happens error codes, consult with Hyundai service center to repair the fault. 3-33...
  • Page 83 DISPLAY DURING AEB-MODE Symbol Meaning Remarks K1..K3 Calibrating clutch K1...K3, KV or KR KV, KR resp. _and Kx Wait for start, initialization of clutch Kx, x : 1, 2, 3, V, R and Kx Fast fill time determination of clutch Kx =and Kx Compensating pressure determination of clutch Kx...
  • Page 84 INITIALIZING THE INCHING SENSOR Start engine after parking the truck on flat floor and blocking wheels. Release parking brake and keep neutral gear shift. Adjust the inching sensor linkage so that the regular voltage is supplied to inching sensor when operating the pedal.

  • Page 85: Switches

    6. SWITCHES Remote control lever type Main light switch Work lamp switch Hazard switch(opt) Beacon lamp switch(opt) Cover Parking brake switch Transmission shift mode switch Inching switch Fuel warmer switch In/decrement switch SCR cleaning switch Power/standard switch Rear wiper/washer switch Top wiper/washer switch(opt) Air compressor switch (opt) Seat heater switch (opt)
  • Page 86 Fingertip type Main light switch Work lamp switch Hazard switch(opt) Beacon lamp switch(opt) Parking brake switch Power/standard switch Rear wiper/washer switch Top wiper/washer switch(opt) Air compressor switch (opt) Seat heater switch (opt) Cooling fan control switch (opt) Cover SCR cleaning switch Switch panel Cover Inching switch...
  • Page 87 START SWITCH There are three positions, OFF, ON and START. (OFF) : None of electrical circuits activate. (ON) : All the systems of truck operate. (START) : Use when starting the engine. Release key immediately after starting. Before starting, set gear selector lever at NEUTRAL and place 77073CD41 parking brake switch to LOCK position.
  • Page 88 WORK LAMP SWITCH This switch is used to operate the work lamps by two steps. First step : Front work lamp comes ON. Second step : Rear work lamp comes ON. 180D9OM16 TRANSMISSION SHIFT MODE SWITCH Three modes are available for operator's preference and job condition. Manual mode ( ) Press the top of the switch for the manual mode of the autoshift function.
  • Page 89 FUEL WARMER SWITCH This switch is used to heat the fuel of pre-heater. 35D9AOM19 BEACON LAMP SWITCH (OPTION) This switch turn ON the strobe light. 35D9AOM18 INC/DECREMENT SWITCH 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.
  • Page 90 CAB LAMP SWITCH This switch turns ON the cab room lamp. 73033CD24 MULTI FUNCTION SWITCH Front wiper and washer switch When the switch is in J position, the wiper moves intermittently. When placed in position, the wiper moves continuously. If you push the grip of the lever, washer liquid will be sprayed and the wiper will be activated 2-3 times.
  • Page 91 SCR CLEANING SWITCH This switch is used to select the cleaning function of the SCR. Inhibit position ( ) The inhibit position disallows any automatic or manual SCR cleaning. This may be used by operator to prevent SCR cleaning when the truck is operating in a hazardous environment is concerned about 50D9OM21A high temperature.
  • Page 92 AIR COMPRESSOR SWITCH (option) This switch is used to activate the air compressor. 110D9CD61 SEAT HEAT SWITCH (option) This switch is used to heat the seat. 110D9CD62 COOLING FAN CONTROL SWITCH (option) This switch use to control the cooling fan. AUTO This switch has three positions.

  • Page 93: Control Device

    7. CONTROL DEVICE Fingertip type Lift lever Tilt lever Auxiliary 1 lever (opt) Auxiliary 2 lever (opt) Remote control lever type Steering wheel adjusting lever Lift lever Tilt lever Steering wheel 3-spool lever (opt) Gear selector lever 4-spool lever (opt) Inching pedal 5-spool lever (opt) Brake pedal...
  • Page 94 LIFT LEVER Lift Pull the lever back to lift the forks. Lower Lower Push the lever forward to lower the load. Lift Holding When the lever is released, the lifting or lowering action stops. 50D9CD12 Lifting speed is controlled by lift lever and accelerator pedal. Lowering speed is controlled by lever only.
  • Page 95 LEVER FOR SIDE SHIFT WITH FORK POSITIONER Fork positioner (synchronizer type) Outstrech the forks Outstrech Push the lever forward to outstrech simultaneously outward of the both forks. Pucker up Pucker up the forks Pull the lever backward to pucker up simultaneously inward of the both forks.
  • Page 96 GEAR SELECTOR LEVER This lever is used for gear selection, forward 3 stages and reverse 3 Acceleration stages. If you push the gear selector lever, the truck moves forward, but Deceleration pulling the gear selector lever, the truck moves backward. Forward If you turn the gear selector lever forward, the truck increases the speed, but if you turn the gear selector lever backward, the truck...
  • Page 97 STEERING WHEEL ADJUSTING LEVER By pulling down the lever, the wheel is adjustable to tilt. - Tilting angle : 40˚ By pulling up the lever, the wheel is adjustable to telescope. - Telescopic stroke : 80 mm Release the lever to lock the steering wheel in the desired 110D9CD70 position.

  • Page 98: Air Conditioner And Heater

    8. AIR CONDITIONER AND HEATER Fuel auto air conditioner and heater are equipped for pleasant operation against outside temperature and defrost on window glass. Fan speed control knob Outlet control button Air conditioner button Air inlet control button Temperature control knob Air conditioner switch 160D9LCD90 AIR CONDITIONER BUTTON...
  • Page 99 OUTLET CONTROL BUTTON There are five kinds of air flow. Face Rear Face and rear Face and defrost Defrost The pilot lamp is turned ON when the button is pushed. 50D9CD51 TEMPERATURE CONTROL KNOB This knob regulates the temperature of air. Right side (red zone) : Cool down air temperature Left side (blue zone) : Heat up air temperature 50D9CD53...

  • Page 100: Others

    9. OTHERS Front Rear Radio and USB player Cigar lighter 12V socket Fuse box Handsfree (option) Remote controller (option) Seat Fingertip type 12V socket Remote controller (option) Handsfree (option) 160D9LCD09 3-51...
  • Page 101 CIGAR LIGHTER This can be used when the engine starting switch is ON. The lighter can be used when it springs out in a short while after being pressed down. Service socket 73033CD49 Use cigar lighter socket when you need emergency power. Do not use the lighter exceeding 24 V, 100 W.
  • Page 102 RADIO AND USB PLAYER BASIC FUNCTIONS LCD display 75793CD62-2 FRONT PANEL PRESENTATION -------- Audio selection button ------- Preset memory button 5 D- ---------------- Directory down -------- Audio selection knob -------- Preset memory button 6 D+ --------------- Directory up -------- Power and volume button -------- Aux function MODE -------- Mode button...
  • Page 103 GENERAL Power and volume button Power ON/OFF button Press power button to turn the unit ON or OFF shortly. When the power is ON, the previous mode (last memory) will appear. Volume up / down control 75793CD66 Turn volume up / down button right to increase the volume level. The level will be shown in VOLUME xx on the LCD display.
  • Page 104 HANDSFREE (OPTION) Allow you to dial a call or to have a conversation without holding your handset. Use the remote controller when making and answering a calls or ring off. Indicator lamp Private call jack socket Handsfree jack socket USB socket Mobile phone stroage box 12V socket 300D9CD51...
  • Page 105 Handsfree jack socket Connect the jack cable when call by handsfree. Use the special adapter when jack cable is not interchangeable. Check the jack type of mobile phone before use. 21093CD51D Indicator lamp This lamp is turned ON when the handsfree mode selected. 21093CD51E 3-68...
  • Page 106 (connection process of the mobile phone and handsfree), you can Call button hear beep sounds three times. 55I3CD26 The mobile phone finds bluetooth named " HYUNDAI". Select "HYUNDAI" and set "connect with Bluetooth on the mobile phone". HYUNDAI · Default password : 0000 PAIRING 55I3CD27 The Bluetooth pairing is made, the LCD screen shows "CONNECTED".
  • Page 107 REMOTE CONTROLLER (OPTION) Radio handsfree jack External speaker LED (null) External speaker microphone (null) Handsfree jack MIC Power/volume switch External speaker switch (null) Handsfree mode button CALL button SEEK button SEEK button MODE button MUTE button TALK button Radio calling mode button 55I3CD31 Power and volume switch This switch is used to turn the audio or handsfree ON or OFF.
  • Page 108 Handsfree MIC This MIC transfers user voice to receiver of the call when making a call by handsfree. 55I3CD31D Seek button If this button pressed, the radio automatically stops at the next frequency of broadcasting for your listening. This button enable to select the song of the MP3 from USB. : Turn a station of higher frequency and the next song of the MP3.
  • Page 109 Radio calling mode button Press this button, activated or deactivated the radio handsfree function. As long as you do not press this button, you can hear the other party. 55I3CD31H The LED is turned ON when this button is activated. The LED turned OFF when the audio mode or the mobile phone handsfree calling mode is activated.

  • Page 110: Operator Maintenance And Care

    Do not make repairs yourself unless you are trained in lift truck repair procedures and authorized by your employer. Have a qualified mechanic make repairs using genuine HYUNDAI or HYUNDAI- approved parts. Do not operate a truck if it is in need of repair. If it is in an unsafe condition, remove the key Do not operate a truck if it is in need of repair.
  • Page 111 2) 2) FUNCTIONAL CHECKS FUNCTIONAL CHECKS Check the operation of the truck as follows. ※ Before performing these checks, familiarize yourself with the starting, operating, and Before performing these checks, familiarize yourself with the starting, operating, and shutdown procedures in Section 5 of this manual. Also, know the safety rules given in shutdown procedures in Section 5 of this manual.

  • Page 112: Suggestion For New Truck

    2. SUGGESTION FOR NEW TRUCK 2. SUGGESTION FOR NEW TRUCK It takes about 100 operation hours to enhance its designed performance. Operate according to below three steps and avoid excessive operation for the initial 100 hours. Avoid excessive operation for Service meter Load initial 100 hours...

  • Page 113: Fuel Safety Practices

    3. FUEL SAFETY PRACTICES 3. FUEL SAFETY PRACTICES REFUELING DIESEL TRUCKS 100D7OM106 Stop the engine when refueling. Stop the engine when refueling. All lights and flames shall be kept at a All lights and flames shall be kept at a safe distance while refueling.

  • Page 114: Starting And Operating Procedures

    5. STARTING AND OPERATING PROCEDURES 5. STARTING AND OPERATING PROCEDURES 1. BEFORE OPERATING THE TRUCK 1. BEFORE OPERATING THE TRUCK Be sure that you have read and understand the information in this Operator's Manual and are trained and authorized before operating the lift truck. A lift truck can be dangerous if not used properly.

  • Page 115: Check Before Operation

    2. CHECK BEFORE OPERATION 2. CHECK BEFORE OPERATION The Occupational Safety and Health Act (OSHA) required that truck users examine their trucks before each shifts to be sure they are in safe working order. Defects when found shall be immediately reported and corrected. The truck shall be taken out of service until it has been restored to safe operating condition.

  • Page 116: Check Before Starting Engine

    3. CHECK BEFORE STARTING ENGINE CHECK FOR WATER OR OIL LEAKAGE Walk around your HYUNDAI truck and check for water, oil or hydraulic leakage. Examine truck for obvious damage. Check cabin, backrest and forks for crack or obvious damage. If any damage or leaks are detected contact your HYUNDAI dealer or tire repair shop.
  • Page 117 3) 3) CHECK COOLANT LEVEL CHECK COOLANT LEVEL If the cooling water in the radiator reservoir tank is not within normal range when cool, add water to the FULL line. FULL ※ Normal Always check the coolant level in the radiator reservoir Always check the coolant level in the radiator reservoir tank prior to beginning of daily operation of the truck.
  • Page 118 5) 5) CHECK FAN BELT CHECK FAN BELT An deflection method can be used to check belt tension by applying 11 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 adjusted.
  • Page 119 (U.S.gal) V - mast TS - mast Level gauge Lower limit 182 (48.1) V300 ~ 700 TS395 ~ 750 160D-9L, 160D7MA14 180D-9B Upper limit 197 (52.0) VS300 ~ 600 CHECK PREFILTER WIF (Water in fuel) warning lamp. If the warning lamp stays on, drain the water from the prefilter.
  • Page 120 MULTI FUNCTION SWITCH MULTI FUNCTION SWITCH Front wiper and washer switch Front wiper and washer switch O J Ⅰ Ⅱ ① When the switch is in J position, the wiper moves intermittently. ② When placed in Ⅰ or Ⅱ position, the wiper moves continuously. ③...
  • Page 121 CHECK AXLE OIL LEVEL CHECK AXLE OIL LEVEL Remove the plug and check the oil amount. Differential gear If the oil level is at the hole of the plug, it is Oil fill & normal. level plug If the oil level is below the plug hole, supply oil through the plug hole.

  • Page 122: Seat Adjustment

    4. SEAT ADJUSTMENT 4. SEAT ADJUSTMENT 1) 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. (1) (1) Forward / Backward adjustment Forward / Backward adjustment ①...

  • Page 123: Starting From A Safe Condition

    5. STARTING FROM A SAFE CONDITION 5. STARTING FROM A SAFE CONDITION Always start from a safe condition. LOCK Before operating a lift truck, make sure that : · You are safely seated in the truck. · Seat belt is buckled up. ·...

  • Page 124: General Starting And Operating Tips

    6. GENERAL STARTING AND OPERATING TIPS 6. GENERAL STARTING AND OPERATING TIPS Before you start the truck, make sure that you have taken all the above-mentioned precautions, you have read this manual, you are starting from a safe condition, with the gear selector lever in NEUTRAL, the seat adjusted, and your seat belt buckled.

  • Page 125: Starting And Stopping The Engine

    7. STARTING AND STOPPING THE ENGINE 7. STARTING AND STOPPING THE ENGINE 1) 1) CHECK INDICATOR LIGHTS CHECK INDICATOR LIGHTS Gear selector lever Parking brake switch Check if the parking brake switch is in the LOCK position. Check if the gear selector lever is in neutral position.
  • Page 126 3) 3) STARTING ENGINE IN A COLD WEATHER STARTING ENGINE IN A COLD WEATHER ※ Sound horn to warn surroundings after Sound horn to warn surroundings after checking if there are obstacles in the area. checking if there are obstacles in the area. ※...
  • Page 127 INSPECTION AFTER ENGINE START INSPECTION AFTER ENGINE START 4) 4) Inspect and confirm the following after engine starts. Is the level gauge of hydraulic oil tank in the normal level? Are there leakages of oil or water? Are all the warning lamps OFF? Check the following after warming up operation.
  • Page 128 Check warning lamps. E/G COOLANT SEAT BELT ENGINE CHECK FUEL LOW LEVEL T/M OVERHEAT SCR CLEANING DEF LOW ENGINE STOP OVERHEAT WARNING LAMP WARNING LAMP WARNING LAMP WARNING LAMP WARNING LAMP WARNING LAMP WARNING LAMP WARNING LAMP E/G OIL BRAKE OIL BRAKE OIL AIR CLEANER WATER IN FUEL...
  • Page 129 5) 5) TRANSMISSION COLD STARTING TRANSMISSION COLD STARTING At an oil temperature in the shifting circuit < -12 ˚C, the transmission must be warmed-up for some minutes. This must be carried out in neutral with an increased engine speed. Until this oil temperature is reached, the electronics remains in neutral, and the symbol of the cold start phase will be indicated on the display.

  • Page 130: Warming-Up Operation

    8. WARMING-UP OPERATION 8. WARMING-UP OPERATION ※ The most suitable temperature for the hydraulic Gear selector lever oil is about 50 ˚C (112 ˚F). Parking brake switch It can cause serious trouble in the hydraulic system by sudden operation when the hydraulic oil temperature is below 25 ˚C (77 ˚F).

  • Page 131: Levers And Pedals

    9. LEVERS AND PEDALS 9. LEVERS AND PEDALS 1) 1) POSITIONING FORKS AND MAST POSITIONING FORKS AND MAST When driving, with or without a load, it is a good practice to always raise the forks slightly and tilt the mast backward. Raising the forks and tilting them back prevents the fork tips from catching on possible obstructions and reduce the wear on the fork blades from striking or dragging on the floor or ground.
  • Page 132 2) 2) SELECTING DIRECTION OF TRAVEL SELECTING DIRECTION OF TRAVEL Push the gear selector lever forward, center it , or pull it back for FORWARD, NEUTRAL, or REVERSE, respectively. Forward Traction is disabled in NEUTRAL. Neutral Reverse 110D9OM95 3) 3) ACCELERATOR PEDAL ACCELERATOR PEDAL With the parking brake released and the gear selector lever in...

  • Page 133: Traveling Of The Truck

    10. TRAVELING OF THE TRUCK 10. TRAVELING OF THE TRUCK 1) 1) BASIC OPERATION BASIC OPERATION Tilt back fully (1) (1) Traveling posture Traveling posture Lift the forks so that the forks are placed 15~ 20 cm (6~8 in) above the ground and tilt back the mast fully.
  • Page 134 When traveling at high speed, do not When traveling at high speed, do not abruptly decelerate by using the gear abruptly decelerate by using the gear selector lever, to slow down instead press selector lever, to slow down instead press the brake pedal.
  • Page 135 Stopping the truck Stopping the truck (6) (6) Gear selector lever ① Press the brake pedal to stop the truck. Parking brake switch ② Put the gear selector lever in the neutral position. ③ Put the parking brake switch in LOCK position. 160D9LOP14 ④...
  • Page 136 (7) (7) Stopping engine Stopping engine ※ Gear selector lever If the engine is abruptly stopped before it has If the engine is abruptly stopped before it has Parking brake switch c o o l e d d o w n , i t s s e r v i c e l i f e m a y b e c o o l e d d o w n , i t s s e r v i c e l i f e m a y b e shortened.

  • Page 137: Operating Safely

    11. OPERATING SAFELY 11. OPERATING SAFELY Safe operation is the responsibility of the operator. WATCH WHERE YOU ARE GOING. DON’T GO IF YOU CAN’T SEE.. WATCH WHERE YOU ARE GOING. DON’T GO IF YOU CAN’T SEE.. 1) 1) Before driving, check all around to be sure that your intended path of travel is clear of obstructions and pedestrians.
  • Page 138 Travel with the fork carriage tilted back and raised only enough to fully clear the ground or obstacles. When the carriage (load) is in an elevated position the stability of the truck is reduced. Do not elevate the load except during stacking. 5) 5) GRADES, RAMPS, AND INCLINES..

  • Page 139: Load Handling

    12. LOAD HANDLING 12. LOAD HANDLING 1) 1) GENERAL GENERAL Handle only loads that are within the truck rated capacity as shown on the nameplate. This rating specifies the maximum load that should be lifted. However, other factors such as special load handling attachments, load having a high center of gravity, or uneven terrain may dictate that the safe working load be less than the rated capacity.
  • Page 140 2) 2) ADJUSTING THE LOAD FORKS ADJUSTING THE LOAD FORKS The load forks are adjustable on the hanger, carriage. Forks should be spaced as far apart as the load will allow. Both forks should always be the same distance from the center of the fork carriage.
  • Page 141 4) 4) TRAVELING WITH LOAD TRAVELING WITH LOAD Travel with load or carriage as low as possible and tilted back. Never travel with the load or carriage raised (elevated) in a high position. Do not elevate the load except during stacking. Observe all traffic regulations and watch for other traffic, pedestrians, and safe clearances.
  • Page 142 5) 5) PICKING UP AND MOVING LOADS PICKING UP AND MOVING LOADS When picking up a load from the ground, approach the load slowly and carefully align the truck square with the load. The forks should be adjusted to fit the load or pallet being handle and spread as wide as possible to provide good stability and balance.
  • Page 143 7) 7) STACKING STACKING To put a load on a stack To put a load on a stack (1) (1) ① Aproach slowly and align the lift truck and load squarely with the stack. D35AOM137 ② Raise the load as the lift truck nears the stack. D35AOM138 ③...
  • Page 144 (2) (2) To move a load from a stack To move a load from a stack Approach the stack carefully, truck lined up squarely with the load. With mast vertical, raise the forks to the correct height for freely engaging the load pallet. Adjust fork angle as necessary to fit squarely under the load.

  • Page 145: Shut Down Procedure

    13. SHUT DOWN PROCEDURE 13. SHUT DOWN PROCEDURE ※ Always leave your lift truck in a safe condition. Always leave your lift truck in a safe condition. 1) 1) WHEN YOU LEAVE YOUR TRUCK, OR PARK IT, FOLLOW THESE SAFETY RULES WHEN YOU LEAVE YOUR TRUCK, OR PARK IT, FOLLOW THESE SAFETY RULES Park in a safe area away from normal traffic.

  • Page 146: Storage

    14. STORAGE 14. STORAGE 1) 1) BEFORE STORAGE 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.

  • Page 147: Transport

    PRECAUTIONS FOR LOADING AND UNLOADING PRECAUTIONS FOR LOADING AND UNLOADING Contact your HYUNDAI forklift distributor for advice regarding transportation of the truck. When loading or unloading the truck on or from a transporter, using loading ramp, the following precautions must always be observed.

  • Page 148: Loading And Unloading By Crane

    16. LOADING AND UNLOADING BY CRANE Check the specification of the truck when you are going to hoist the truck. Use long wire rope and stay to keep the Stay Wire rope distance with the truck as it should avoid To lift touching with the truck body.

  • Page 149: Emergency Starting And Towing

    Check that the counterweight bolts are in place and properly torqued. (This bolt is made of a special high tensile steel and is not commercially available. Replace it, when necessary, only with a genuine HYUNDAI replacement part). Use an approved, solid metal tow bar with towing couplers that connect to the towing pins in the counterweights.
  • Page 150 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: Parking Brake Release

    2. PARKING BRAKE RELEASE 2. PARKING BRAKE RELEASE Parking brake is operated by the spring force and released by hydraulic pressure. If the engine or transmission does not operate, the parking brake will be operated to stop the truck. For an emergency, the parking brake can be released as below. 100D7BS117 Thrust bolt Screw cap...

  • Page 152: How To Use Battery Jumper Cables

    3. HOW TO USE BATTERY JUMPER CABLES 3. HOW TO USE BATTERY JUMPER CABLES If your lift truck battery is discharged (dead), you can start your lift truck by jumping it from another lift truck that has a 24V negative-ground electrical system. The "Booster" battery must be fully charged and in good condition.
  • Page 153 Connect the jumper cables in the following To ground sequence: To starter switch ⓐ Connect a jumper cable from the positive Charged battery (+; red) terminal on one battery to the positive (+; red) terminal on the other battery. Never connect positive (+; red) to negative (-;...

  • Page 154: Planned Maintenance And Lubrication

    Specifications for selected components, fuel, lubricants, critical bolt torques, refill capacities, and settings for the truck are found in section 8. If you have needed for more information on the care and repair of your truck, see your HYUNDAI dealer.

  • Page 155: Safe Maintenance Practices

    Carefully read and understand these instructions and the specific maintenance procedures before attempting to do any repair work. When in doubt of any maintenance procedure, please contact your local HYUNDAI dealer. Powered industrial trucks can become hazardous if maintenance is neglected. Therefore, suitable maintenance facilities and trained personnel and procedures shall be provided.
  • Page 156 Before leaving the truck. Stop the truck. Fully lower the load-engaging means: mast, carriage, forks or attachments. Put the gear selector lever in NEUTRAL. Put the parking brake switch in the LOCK position. Stop the engine. Turn the start switch to the OFF position. Put blocks at the wheels if the truck must be left on an incline.
  • Page 157 Parts, including tires, are to be installed per the manufacturer's procedures. Always use genuine HYUNDAI or HYUNDAI-approved parts. When removing tires follow industry safety practices. Most importantly, deflate pneumatic tires completely prior to removal.

  • Page 158: Instructions Before Maintenance

    3. INSTRUCTIONS BEFORE MAINTENANCE 3. INSTRUCTIONS BEFORE MAINTENANCE 1) 1) INTERVAL OF MAINTENANCE INTERVAL OF MAINTENANCE You may inspect and service the truck by the period as described at based on service meter of LCD. Shorten the interval of inspect and service depending on site condition.(Such as dusty area, quarry, sea shore and etc.) Practice the entire related details at the same...
  • Page 159 Engine and hydraulic components have been preset in the factory. Do not allow unauthorized personnel to reset them. Ask to your local dealer or Hyundai for maintenance advise it unknown. Drain the used oil and coolant in a container and handle according to the method of handling for industrial waste to meet with regulations of each province or country.
  • Page 160 Replace clamp at the same time if the hose clamp is cracked when checking and replacing hose. EMISSION-RELATED COMPONENTS WARRANTY (USA AND CANADA ONLY) Hyundai shall have obligation under the EPA (Environmental Protection Agency) regulation of warranty about Emission-related components. This warranty shall exist for 3,000 hours or five years, whichever occurs first.

  • Page 161: Planned Maintenance Intervals

    4. PLANNED MAINTENANCE INTERVALS 4. PLANNED MAINTENANCE INTERVALS 1) 1) MAJOR COMPONENTS LOCATION MAJOR COMPONENTS LOCATION 9 10 11 15 12 14 160D9LOM21 Mast 10 Torque converter 19 Seat Lift cylinder 11 Engine 20 Cabin Steering unit 12 Steering cylinder 21 Steering wheel Tilt cylinder 13 Hydraulic pump...
  • Page 162 2) 2) MAINTENANCE CHECK LIST MAINTENANCE CHECK LIST (1) (1) EVERY 10 HOURS SERVICE EVERY 10 HOURS SERVICE Check items Service Remarks Visual inspection ·Truck for obvious damage and leaks. Check, Repair or Replace 7-15 ·Warning plates and decals. Check, Replace 7-15 ·Condition of tires and wheels.
  • Page 163 (3) (3) INITIAL 50 HOURS SERVICE INITIAL 50 HOURS SERVICE Check items Service Remarks Engine oil and filter Change/Replace 7-20 Pilot line filter element Replace 7-39 INITIAL 100 HOURS SERVICE INITIAL 100 HOURS SERVICE Check items Service Remarks Axle gear oil (differential + hub x 2) Change 7-46 Transmission oil and filter...
  • Page 164 EVERY 4500 HOURS SERVICE Check items Service Remarks Aftertreatment DEF dosing unit filter Replace 7-32 (10) (10) EVERY 5000 HOURS SERVICE EVERY 5000 HOURS SERVICE Check items Service Remarks Replace 7-38 Hydraulic oil (* Hyundai genuine long life hydraulic oil 7-11...
  • Page 165 (11) (11) WHEN REQUIRED WHEN REQUIRED Check items Service Remarks Fuel system ·Fuel tank Drain or Clean 7-29 ·Prefilter (water, sediment) Check, Drain 7-29 ·Fuel filter Replace 7-30 Engine lubrication system ·Engine oil Change 7-20 ·Engine oil filter Replace 7-20 Engine cooling system ·Coolant Add, Change...

  • Page 166: Maintenance Chart

    5. MAINTENANCE CHART 5. MAINTENANCE CHART 1) 1) MAINTENANCE LOCATIONS MAINTENANCE LOCATIONS 160D9LMA011 CAUTION CAUTION ※ Service intervals are based on the hourmeter 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.
  • Page 167 Replace 5000 Hours 21 Hydraulic oil* Change *3 182 (48.1) Conventional hydraulic oil Hyundai genuine long life hydraulic oil See page 5-6 for details. ※ Oil symbol Refer to the recommended lubricants for specification. DF : Diesel fuel HO : Hydraulic oil...

  • Page 168: How To Perform Planned Maintenance

    6. HOW TO PERFORM PLANNED MAINTENANCE 6. HOW TO PERFORM PLANNED MAINTENANCE 1) 1) VISUAL INSPECTION VISUAL INSPECTION First, perform a visual inspection of the lift truck and its components. Walk around the truck and take note of any obvious damage or maintenance problems.
  • Page 169 Height Model (mm) difference (mm) below 1500 Height difference 160D-9L, 180D-9B above 1500 300D9OM150 If the fork blade at the heel is worn down by more than 10%, the load capacity is reduced and the fork must be replaced. Shank Inspect the forks for twists and bends.
  • Page 170 6) 6) WHEEL AND TIRES WHEEL AND TIRES Check the condition of the drive and steering wheels and tires. Remove objects that are embedded in the tread. Inspect the tires for excessive wear and breaks or chunking out chunking out. Check all wheel lug nuts or bolts to be sure none are loose or missing.
  • Page 171 7) 7) TILTING CABIN TILTING CABIN Keep clearance of people except the operator Keep clearance of people except the operator before tilting the cabin. before tilting the cabin. Lock lever Before tilting the cabin, make sure that the Before tilting the cabin, make sure that the mast is vertical or tilted forward.
  • Page 172 Do not operate cabin tilting function while the power is ON or engine is running. START (X) ON (X) OFF (O) 110D9MI65 Do not operate the tilt control switch or any control parts while servicing under the tilted cabin. It can cause severe injury or death. WARN OPERATE 110D9MI64...

  • Page 173: Service Instruction

    7. SERVICE INSTRUCTION 7. SERVICE INSTRUCTION 1) 1) CHECK ENGINE OIL LEVEL CHECK ENGINE OIL LEVEL Check the oil level with the truck on a flat ground Dipstick before starting the engine. Pull out the dipstick and wipe with a clean cloth. Check the oil level by inserting the dipstick completely into the hole and pulling out again.
  • Page 174 Apply a light film of lubricating oil to the gasket sealing surface before installing the filter. ※ Fill the filter with clean lubricating oil. Fill the filter with clean lubricating oil. The lack of lubrication during the delay until The lack of lubrication during the delay until the filter is pumped full of the start-up can the filter is pumped full of the start-up can damage the engine.
  • Page 175 3) 3) 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 reservoir tank if coolant is not sufficient. The coolant level should indicate between FULL and LOW.
  • Page 176 Wait until the temperature is below 50 ˚C Wait until the temperature is below 50 ˚C (122 ˚F) before removing the coolant system (122 ˚F) before removing the coolant system pressure cap. pressure cap. Failure to do so can cause personal injury Failure to do so can cause personal injury from heated coolant spray.
  • Page 177 ③ Fill the cooling system with clean water. ※ Be sure to vent the engine and aftercooler Be sure to vent the engine and aftercooler for complete filling. for complete filling. ※ Do not install the surge tank cap or the new Do not install the surge tank cap or the new coolant filter.
  • Page 178 160D7A6MI02 6) 6) CHECK CHARGE AIR COOLER CHECK CHARGE AIR COOLER Inspect the charge air cooler for dirt and debris blocking the fins. Check for cracks, holes, or other damage. If damage is found, please contact Hyundai distributor. 160D7A6MA21 7-25...
  • Page 179 7) 7) FAN BELT FAN BELT 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 adjusted.
  • Page 180 9) 9) FAN BELT TENSIONER FAN BELT TENSIONER With the engine stopped, check the tensioner arm, pulley, and stops for cracks. If any cracks are found, the tensioner must be replaced. 2609A6MA23 With the belt installed, verify that neither tension- er arm stop is in contact with the spring case stop.
  • Page 181 CLEANING OF AIR CLEANER CLEANING OF AIR CLEANER (1) (1) Primary element Primary element ① Open the cover and remove the element. ② Wipe all contaminant and debris from inside the housing body. ③ Do not clean the filter element by striking or hitting the filter against any object to shake the debris from the filter element.
  • Page 182 FUEL TANK FUEL TANK Fuel cap Fill fuel fully when system the operation to minimize water condensation, and check it with fuel gauge before starting the truck. Drain the water and sediment in the fuel tank by Fuel tank opening the drain plug. ※...
  • Page 183 REPLACEMENT OF FUEL FILTER REPLACEMENT OF FUEL FILTER ※ Clean all around the filter area before Clean all around the filter area before remove the fuel filter. Dirt or contami- remove the fuel filter. Dirt or contami- nants can damage the fuel system. nants can damage the fuel system.
  • Page 184 BLEEDING THE FUEL SYSTEM BLEEDING THE FUEL SYSTEM Air vent plug Loosen air vent plug at the outlet of Open Close prefilter. Do hand-priming the lift pump repeatedly until air bubbles comes out from air vent Lift pump plug hole completely. Tighten air vent plug to its origin position.
  • Page 185 DEF/AdBlue® DEF/AdBlue® TANK TANK DEF/AdBlue tank ® The DEF/AdBlue tank level must be checked daily with DEF/AdBlue ® level gauge. DEF/AdBlue level gauge It is unlawful to tamper with or remove any It is unlawful to tamper with or remove any component of the aftertreatment system.
  • Page 186 DEF/ADBLUE® DOSING UNIT FILTER DEF/ADBLUE® DOSING UNIT FILTER (1) (1) Remove Remove ※ There may be residual DEF in the filter There may be residual DEF in the filter housing. A collection container placed below housing. A collection container placed below the DEF filter cap is recommended.
  • Page 187 ④ Clean the aftertreatment DEF dosing unit cap and threads on the dosing unit with warm water and a clean cloth. ※ Never operate the truck with the DEF cap Never operate the truck with the DEF cap removed. removed. 250D9DEF03 (3) (3) Install...
  • Page 188 CRANKCASE BREATHER FILTER CRANKCASE BREATHER FILTER ※ Do not use pneumatic tools to remove the Do not use pneumatic tools to remove the Capscrew breather cover capscrews. Damage to the breather cover capscrews. Damage to the rocker cover can result. rocker cover can result.
  • Page 189 If the gasket was removed, install the gasket into the rocker lever cover groove starting with the tab end first. Then install the corners opposite the gasket tab end. Finish by pushing in the sides (see illustration). Gently push the gasket down into the groove. Do not used a finger to trace the gasket around into the groove during installation, as this will stretch the gasket, making it difficult to fully seat into the...
  • Page 190 HYDRAULIC OIL CHECK HYDRAULIC OIL CHECK Level gauge Lower the forks on the ground at a flat location Red line as in the illustration. Stop the engine and then leave for about 5 minutes. Check the oil level at the level gauge. The level gauge is located on the left side of the hydraulic oil tank.
  • Page 191 CHANGE THE HYDRAULIC OIL CHANGE THE HYDRAULIC OIL Air breather Lower the forks on the ground and extend the tilt cylinder to the maximum. Loosen the cap and relieve the pressure in the tank. Prepare a suitable drain pan. To drain the oil loosen the drain plug. After draining oil, tighten the drain plug.
  • Page 192 REPLACEMENT OF ELEMENT IN HYDRAULIC REPLACEMENT OF ELEMENT IN HYDRAULIC TANK BREATHER TANK BREATHER Screw Air breather Loosen the cap and relieve the pressure in the Cover tank. Filter Loosen the screw and remove the cover. Pull out the element. Replace the element with a new one.
  • Page 193 Model Size Pressure Normal 160D-9L, 12.00-20, 20PR 10.2 kgf/cm (145 psi) 180D-9B Continuous operation will produce heat and i n c r e a s e p r e s s u r e o n t i r e . B u t s u c h phenomenon was already taken into account when designing a tire.
  • Page 194 Do not use recycled wheel parts. Do not use recycled wheel parts. When removing lockering or inflating tire, use When removing lockering or inflating tire, use safety cable or chain to ensure safety. safety cable or chain to ensure safety. B e s u r e t o b l e e d a i r b e f o r e r e m o v i n g B e s u r e t o b l e e d a i r b e f o r e r e m o v i n g lockering.
  • Page 195 ② Loosen slightly all wheel mounting. ·Tools : Socket 32 mm Torque wrench Extension bar ③ Lift the truck with a jack. ④ Loosen all wheel mounting nuts and replace the tire. Torque wrench 160D9LMI37 (3) (3) Direction of tire to be installed Direction of tire to be installed ①...
  • Page 196 CHECK TRANSMISSION OIL LEVEL CHECK TRANSMISSION OIL LEVEL The oil level check must be carried out as follows; Oil level check (weekly). At horizontally standing truck. Transmission in neutral position. In cold start phase, the engine must be running about 2~3 minutes at idling speed, and the marking on the oil dipstick must then be lying above the cold start mark COLD.
  • Page 197 Remove the transmission oil filter cartridge. Dispose of the used transmission oil filter cartridge properly. Clean the filter cartridge mounting base. Remove any part of the filter cartridge gasket that remains on the filter cartridge mounting base. Transmission oil filter 110D9MI43 Apply a light coat of oil to the gasket of a new transmission oil filter cartridge.
  • Page 198 CLEANING TRANSMISSION AIR BREATHER CLEANING TRANSMISSION AIR BREATHER Remove dust or debris around the air breather. Air breather Remove the air breather and wash it with a cleaning oil. 110D9MI45 CHECK AND SUPPLYING AXLE OIL CHECK AND SUPPLYING AXLE OIL Move the truck to flat ground.
  • Page 199 If the oil level is below the plug hole, supply oil Planetary gear 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 brake and fix the tires with blocks. As the truck is hot after operation, wait until As the truck is hot after operation, wait until the temperature has dropped.
  • Page 200 Supply oil into the differential gear and the Differential gear planetary gear. Oil fill & ·Oil amount : 19ℓ(5.0 U.S. gal) level plug Supply oil until it overflows from the oil filler, then install the plug. As the truck is hot after operation, wait until As the truck is hot after operation, wait until the temperature has dropped.
  • Page 201 LUBRICATION LUBRICATION Lubricate the grease to grease nipple in accordance with lubrication intervals. ※ Shorten lubricating interval when working Shorten lubricating interval when working in the water or dusty place. in the water or dusty place. 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...
  • Page 202 MAINTENANCE OF WORK EQUIPMENT MAINTENANCE OF WORK EQUIPMENT Lubricate to each point of working device. ※ Refer to page 7-48. Refer to page 7-48. Check for wear and tear of work equipment pins and bushings. Check for damage of forks and mast linkage part.

  • Page 203: Electrical System

    8. ELECTRICAL SYSTEM 8. ELECTRICAL SYSTEM 1) 1) WIRING, GAUGES WIRING, GAUGES C h e c k r e g u l a r l y a n d r e p a i r l o o s e o r malfunctioning gauges when found.

  • Page 204: Air Conditioner And Heater

    9. AIR CONDITIONER AND HEATER 9. AIR CONDITIONER AND HEATER CLEANING AND REPLACING FILTER CLEANING AND REPLACING FILTER ※ Always stop the engine before servicing. Always stop the engine before servicing. Open the door, loosen the wing bolt and remove the recirculation plenum assembly.
  • Page 205 REFRIGERANT Equipment contains fluorinated greenhouse gas. Model Type Quantity 160D-9L, 180D-9B HFC-134a 0.55 kg (1.21 lb) 787 CO2 eq. Global warming potential (GWP) is a measure of how much heat a gas traps in the atmosphere relative to that of carbon dioxide (CO2). GWP is calculated in terms of the 100-year warming potential of 1 kg of a greenhouse gas relative to 1 kg of CO2.

  • Page 206: Replacement And Check

    10. REPLACEMENT AND CHECK 10. REPLACEMENT AND CHECK 1) 1) WIRING, GAUGES WIRING, GAUGES Check regularly and repair the loose or malfunctioning gauges when found. 13036MI29 2) 2) BATTERY BATTERY (1) (1) Clean Clean ① Wash the terminal with hot water if it is contaminated, and apply grease to the terminals after washing.
  • Page 207 ② When remounting, connect the ground Connect (-) lead last connection last Neg(-) Do not allow tools to touch the (+) terminal and Do not allow tools to touch the (+) terminal and the body of the truck at the same time. This can the body of the truck at the same time.
  • Page 208 For details of procedures, contact your personal using the correct tools and procedures. For details of procedures, contact your HYUNDAI dealer. Wear safety glasses and a face shield when using compressed air. HYUNDAI dealer. Wear safety glasses and a face shield when using compressed air.
  • Page 209 4) 4) FUSE AND RELAY REPLACEMENT FUSE AND RELAY REPLACEMENT (1) Fuse box #1 (2) Fuse box #2 (3) Relay box #1 (4) Relay box #2 160D9LOM165 ① Turn the starting swich OFF. ② Open the cover of the fuse box or relay box, and replace fuses or relays inside (to open the cover of the fuse box or relay box, push the side of the cover lightly with a finger, and pull the cover forward to remove it.) When replacing the fuse or relay, check the relationship between the fuse or relay and the...
  • Page 210 5) 5) LAMP BULBS REPLACEMENT LAMP BULBS REPLACEMENT Lamp Spec (24V) Head lamp Turn signal lamp Clearance lamp Stop lamp Backup lamp License lamp (option) Beacon lamp (option) Strobe type 110D9OM69 Work lamp (front/rear) LED/HID After checking that the fuse is not blown and that there is no disconnection in the wiring After checking that the fuse is not blown and that there is no disconnection in the wiring harness, replace the lamp bulb.
  • Page 211 (5) (5) Parking brake Parking brake Check the function of the parking brake. Release, then reapply. To check parking brake holding capability, park the lift truck on a grade and apply the parking brake. The parking brake should hold a lift truck with rated load on a 15% grade. Do not operate a lift truck if the service or parking brakes are not operating properly.
  • Page 212 (8) (8) Steering system Steering system ※ The steering system, steering axle, and steering linkage on your truck should be inspected The steering system, steering axle, and steering linkage on your truck should be inspected periodically for abnormal looseness and damage, leaking seals, etc.. Also, be alert for any periodically for abnormal looseness and damage, leaking seals, etc..
  • Page 213 (rear end). Clean and lubricate the mast mounting pin. Lift chains Lift chains (3) (3) Lubricate the entire length of the mast rail lift and carriage chains with HYUNDAI chain and cable lube. 8) 8) AIR CLEANING AIR CLEANING Always maintain a lift truck in a clean condition.
  • Page 214 HYUNDAI chain lubricant is recommended; it is easily sprayed on and provides superior lubrication. Heavy motor oil may also be used as a lubricant and corrosion inhibitor.
  • Page 215 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 chains.

  • Page 216: Handling Truck In Extremely Hot Places

    11. HANDLING TRUCK IN EXTREMELY HOT PLACES 11. HANDLING TRUCK IN EXTREMELY HOT PLACES Pay careful attention particularly to the following Radiator points when handling the truck in extremely hot places. Compressed Scale and rust form more easily in the cooling air gun system, so wash with anticorrosion liquid.

  • Page 217: Cold Weather Operation

    12. COLD WEATHER OPERATION 12. COLD WEATHER OPERATION 1) 1) PREPARATION FOR LOW TEMPERATURE PREPARATION FOR LOW TEMPERATURE Replace lubrication oil with oil of the prescribed viscosity. Fuel of low pour point must be used. ASTM D975 No.1 diesel fuel should be used at ambient temperature lower than -5 ˚C.

  • Page 218: Recommendation Table For Lubricants

    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 ★1 ISO VG15, Conventional hydraulic oil Grease Lithium base grease NLGI No.2 Fuel ASTM D975-No.2...

  • Page 219: Fuel And Lubricants

    14. FUEL AND LUBRICANTS Use only oils listed below or equivalent. Do not mix different brand oil. Capacity (U.S. gal) Ambient temperature C ( F) Service point Kind of fluid 160D-9L, 180D-9B (-58) (-22) (-4) (14) (32) (50) (68) (86) (104)

  • Page 220: Specifications

    8. SPECIFICATIONS 1. SPECIFICATION TABLE C' C 160D9LSP01 Model Unit 160D-9L 180D-9L 18000 (40000) Capacity kg (lb) 16000 (35300) Load center mm (in) 1200 (47.2) 900 (35.4) Weight (Unloaded) kg (lb) 23954 (52810) Lifting height mm (ft · in) 3020 (9' 11") Free lift mm (ft ·...

  • Page 221: Specification For Major Components

    2. SPECIFICATION FOR MAJOR COMPONENTS 2. SPECIFICATION FOR MAJOR COMPONENTS 1) 1) ENGINE ENGINE Item Unit Specification Model Cummins QSB6.7 Type 4 cycle turbocharged, charger air cooled diesel engine Cooling Method Water cooling Number of cylinders and arrangement 6 cylinders, In-line Firing order 1-5-3-6-2-4 Combustion chamber type...
  • Page 222 4) 4) STEERING UNIT STEERING UNIT Item Unit Specification Type Load sensing / Non load reaction / Dynamic signal Capacity cc/rev Rated flow 5) 5) POWER TRAIN DEVICES POWER TRAIN DEVICES Item Specification Model 05 W 340 (ZF SACH) Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio...

  • Page 223: Tightening Torque

    3. TIGHTENING TORQUE Item Size kgf m lbf ft Engine mounting bolt, nut (bracket-frame) M24 3.0 100 15 723 109 Engine Engine mounting bolt (engine-bracket) M12 1.75 12.3 2.4 89.0 17.4 Radiator mounting bolt, nut M12 1.75 12.8 3.0 92 21.7 Hydraulic pump mounting socket bolt M12 1.75 14.7 2.2...

  • Page 224: Troubleshooting

    9 . TROUBLESHOOTING 9 . TROUBLESHOOTING 1. ENGINE SYSTEM 1. ENGINE SYSTEM Trouble symptom Probable cause Remedy ·Low oil level in oil pan. ·Add oil. Oil pressure warning lamp ·Oil filter element clogged. ·Replace element. fails to go out. ·Loose or worn oil pipe joint leaks oil. ·Check and repair.

  • Page 225: Electrical System

    2. ELECTRICAL SYSTEM 2. ELECTRICAL SYSTEM Trouble symptom Probable cause Remedy ·Faulty wiring. ·Check for loose terminal and discon- Lamps dimming even at maxi- mum engine speed. nected wire. ·Improper belt tension. ·Adjust belt tension. Lamps flicker during engine operation. ·Charge lamp defective.

  • Page 226: Torque Flow System

    3. TORQUE FLOW SYSTEM 3. TORQUE FLOW SYSTEM Trouble symptom Probable cause Remedy 1. Excessive oil ·Improper oil level. ·Check oil level. Add or drain oil as temperature rise 1) Torque converter necessary. ·Impeller interfering with surroundings. ·After draining oil from oil tank and transmission, check and replace interfering parts.
  • Page 227 Trouble symptom Probable cause Remedy 3.Low output power ·Insufficient hydraulic pressure : 1) Torque converter - Low oil level. - Check oil level and add oil - Air sucked in. - Check joints and pipes. If necessary, retighten joint or repla- ce packing.
  • Page 228 Trouble symptom Probable cause Remedy 4.Unusual oil pressure ·Control valve malfunctioning. 1) Oil pressure is high (1)Check for spool operation. If necessary, replace valve. (2)Check for clogging of small hole in valve body. If necessary, clean or repair. ·Cold weather. (high oil viscosity) ·When atmospheric temp is below fr- eezing point (when normal oil pressure is recover-...
  • Page 229 Trouble symptom Probable cause Remedy ·Foreign matter intruding into oil pass- ·Disassemble, check and repair or 5. Power is not transmitted (Continue) age to clutch. replace. ·Shaft spline worn. ·Disassemble, check and replace. ·Oil leaks from oil seal. ·Disassemble and check for wear of 6.

  • Page 230: Steering System

    4. STEERING SYSTEM 4. STEERING SYSTEM Trouble symptom Probable cause Remedy ·Low oil pressure. ·Check locknut. Repair. 1. Steering wheel drags. ·Bearing faulty. ·Clean or replace. ·Spring spool faulty. ·Clean or replace. ·Reaction plunger faulty. ·Replace. ·Ball-and-screw assembly faulty. ·Clean or replace. ·Sector shaft adjusting screw excessi- ·Adjust.

  • Page 231: Brake System

    5. BRAKE SYSTEM 5. BRAKE SYSTEM Trouble symptom Probable cause Remedy ·Hydraulic system leaks oil. ·Repair and add oil. 1. Insufficient braking force ·Hydraulic system sucks air. ·Bleed air. ·Disk worn. ·Replace ·Brake valve malfunctioning ·Repair or replace. ·Hydraulic system clogged ·Clean.

  • Page 232: Hydraulic System

    6. HYDRAULIC SYSTEM 6. HYDRAULIC SYSTEM Trouble symptom Probable cause Remedy ·Seal inside control valve defective. ·Replace spool or valve body. 1. Large fork lowering speed. ·Oil leaks from joint or hose. ·Replace. ·Seal inside cylinder defective. ·Replace packing. ·Tilting backward : Check valve defec- ·Clean or replace.

  • Page 233: Mast And Fork

    7. MAST AND FORK 7. MAST AND FORK 1) 1) MAST MAST Problem Problem Cause Cause Remedy Remedy ·Deformed mast or carriage. ·Disassemble, repair or replace. Forks fail to lower. ·Faulty hydraulic equipment. ·See troubleshooting hydraulic pump Fork fails to elevate and cylinders in section 6, hydraulic system.
  • Page 234 2) 2) FORKS FORKS Problem Problem Cause Cause Remedy Remedy Abrasion Long-time operations causes the fork to If the measured value is below the wear and reduces the thickness of the wear limit, replace fork. fork. Inspection for thickness is needed. ·Wear limit : Must be 90% of fork thickness Distortion...

  • Page 235: Testing And Adjusting

    10. TESTING AND ADJUSTING 10. TESTING AND ADJUSTING 1. ENGINE SYSTEM 1. ENGINE SYSTEM 1) 1) EASE OF STARTING, NOISE EASE OF STARTING, NOISE Set gear selector lever at NEUTRAL. Forward Neutral Backward 110D9OM45 Put the parking brake switch in LOCK position.
  • Page 236 The fuel filter cartridge cannot be inspected from the outside, so replace it periodically (refer to SECTION 7. MAINTENENCE AND LUBRICATION). Always use HYUNDAI Forklift genuine parts when replacing the element. After replacing the element, run the engine and check for oil leakage from the filter mount.
  • Page 237 8) 8) CHECK FAN BELT TENSION CHECK FAN BELT TENSION An deflection method can be used to check belt tension by applying 11 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 adjusted.

  • Page 238: Drive System

    2. DRIVE SYSTEM 2. DRIVE SYSTEM 1) 1) GEAR SELECTOR LEVER GEAR SELECTOR LEVER (1) (1) Neutral starting Neutral starting Engine can be started only when the gear selector lever is in neutral position. (2) (2) Shifting forward/reverse Shifting forward/reverse ①...
  • Page 239 (3) (3) Inching pedal Inching pedal ·Adjust stopper bolt (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).

  • Page 240: Travel System

    3. TRAVEL SYSTEM 3. TRAVEL SYSTEM TIRES TIRES Check tire pressure using tire gauge : SEE page 5-3 CHECK BEFORE STARTING ENGINE. Check visually for cracks and damage to tread and side wall. If crack or damage is serious, replace tire. Wear Measure tread of pneumatic tires (tires with air).

  • Page 241: Steering System

    4. STEERING SYSTEM 4. STEERING SYSTEM STEERING WHEEL STEERING WHEEL 30~60mm Set rear wheels facing straight forward, (1.2~2.4 in) then turn steering wheel to left and right. Measure range of steering wheel movement before rear wheel starts to move. Range should be 30 ~ 60 mm at rim of steering wheel.

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180d-9b

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