Hyundai HLF15-5 Manual
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Hyundai HLF15-5 Manual

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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. Step - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-16
15. Operator's safety rules - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-17
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 hiqh loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3
6. Drop-offs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4
7. Right angle stacking - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4
8. Chain slack - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5
9. Pallets and skids - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5
10. Cauting for electrical lines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6
11. Lifting loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-7
1. General locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
2. Data/safety plates and decals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2
3. Instruments and controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-5
4. Indicator symbols - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-8
5. Operating lever and switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-11
6. Fuel system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-16
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Summary of Contents for Hyundai HLF15-5

  • Page 1: Table Of Contents

    CONTENTS 1. SAFETY HINTS 1. Daily inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 2.
  • Page 2 4. OPERATOR MAINTENANCE AND CARE 1. Daily safety inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1 2.
  • Page 3 8. INFORMATION FOR LPG 1. Foreword - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 2.
  • Page 4 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 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 Section 7. Planned Maintenance and Lubrication, describes the PM (Planed Maintenance) program. Section 8. Information for LPG, explains the method of operating HYUNDAI forklift that is powered by LPG.
  • 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 GUIDE 1. DIRECTION The directions of this machine indicate forward, Front backward, right and left when machine is in the travelling direction. Left Right Rear L255OM47 2. SERIAL NUMBER Inform following when you order parts or the machine is out of order. MACHINE SERIAL NUMBER It's shown front of the right side frame.

  • Page 9: Safety Hints

    1. SAFETY HINTS 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. Lift truck mechanics are trained professionals.

  • Page 10: 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. L255OM04 Don't smoke in NO SMOKING areas or when refilling LPG tanks. D35AOM06...
  • Page 11 Don't operate the truck outdoors in rainy day. ※ E xclude the truck equipped cabin. L255OM07 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 12: Seat Belts

    3. SEAT BELTS Always buckle up for the machine equipped with safety belt. L255OM117 Seat belts can reduce injuries. B207OM10...

  • Page 13: No Riders

    4. NO RIDERS The operator is the only one who should be on a truck. L255OM11 Never transport personnel on the forks of a lift truck. L255OM12...

  • Page 14: 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. L255OM13 Watch for people in your work area even if your truck has warning lights or alarms.

  • Page 15: Operator Protection

    6. OPERATOR PROTECTION Keep under the overhead guard. Always keep your body within the confines of the truck. Do not operate truck without overhead guard, unless condition prevent use of a guard. L255OM14...

  • Page 16: Fork Safety

    7. FORK SAFETY Never allow anyone to walk under raised forks. L255OM48 There is special equipment to raise people for overhead work. DO NOT USE LIFT TRUCKS. L255OM50 Always lower the load slowly. Raise and lower with mast vertical or tilted slightly back(Never forward).

  • Page 17: Pinch Points

    8. PINCH POINTS Keep hands, feet and legs out of the mast. D255OM61 Don't use the mast as a ladder. L255OM24 Never try to repair the mast, carriage, chain, or attachment by yourself. Always get a trained mechanic. L255OM25...

  • Page 18: 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 truck is in motion. L255OM26 When handling bulky loads that restrict your vision operate your truck in reverse to improve visibility.

  • Page 19: Grades, Ramps, Slopes And Inclines

    10. GRADES, RAMPS, SLOPES AND INCLINES Never turn on a grade, either loaded or unloaded. Unloaded - Forks downgrade L255OM29 Loaded - Forks upgrade L255OM30 1-11...

  • Page 20: Tip Over

    11. TIP OVER LATERAL TIP OVER Lateral tip over can occur with a combination of speed and sharpness of turn. This combination will exceed the stability of the truck. This condition is even more likely with an unloaded truck. With the load or mast raised, lateral tip over can occur while turning and/or braking when traveling in reverse or accelerating and turning while traveling forward.
  • Page 21 WHAT TO DO IN CASE OF A TIP OVER If your truck starts to tip over, Do not jump. Brace yourself as illustrated right. 1. Make sure your seat belt is fastened securely, if the truck is equipped with seat belt. 2.

  • Page 22: 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. Especially when using elevators, Know the capacity of the elevator you intend to use.

  • Page 23: Parking

    13. PARKING Never park on a grade. L255OM37 Always come to a complete stop before leaving truck. Be sure travel control is in NEUTRAL. L255OM38 Lower forks fully to floor and tilt forward. L255OM39 Set parking brake. Position 1 : Lock Position 2 : Release Turn key to OFF position.

  • Page 24: Step

    14. STEP When getting on or off the machine, use the step provided. L255OM51 Do not jump up or down from the machine. L255OM08 1-16...

  • Page 25: Operator's Safety Rules

    Always buckle up if a seat belt is provided. D35AOM23 Parking brake must be locked in the PARK HYUNDAI POSITION before exiting from the vehicle. 1. Release(Drive) Parking brake must remain locked in the 2. Lock(Park) park position(2) except when an operator is in the normal operating position.

  • Page 26: Operating Hazards

    2. OPERATING HAZARDS 2. OPERATING HAZARDS 1. LOOSE LOADS 1. LOOSE LOADS Loose or unbalanced loads are dangerous. Loose or unbalanced loads are dangerous. Observe these precautions. Observe these precautions. Never carry loose or uneven material. D35AOM39 Center wide loads. D35AOM40 Stack and band loose material.

  • Page 27: 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 28: 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 29: Drop-Offs

    6. DROP-OFFS 6. DROP-OFFS To avoid these hazards, you must: To avoid these hazards, you must: Talk to the truck driver yourself: make sure the driver does not move the trailer until you are done. Apply trailer brakes. Use wheel chocks. Use trailer-to-dock locking system if available.

  • Page 30: Chain Slack

    8. CHAIN SLACK 8. CHAIN SLACK Slack chains mean rail or carriage hang-up. Slack chains mean rail or carriage hang-up. Raise the forks before you move, or broken Raise the forks before you move, or broken chains can result. chains can result. In case forks with loads are stuck while In case forks with loads are stuck while lowering the mast, lift the mast again and...

  • Page 31: Cauting For Electrical Lines

    10. CAUTION FOR ELECTRICAL LINES 10. CAUTION FOR ELECTRICAL LINES When moving the machine with the mast When moving the machine with the mast raised, watch out electrical lines over the raised, watch out electrical lines over the machine. machine. The operating near the electrical lines is very The operating near the electrical lines is very dangerous.

  • Page 32: Lifting Loads

    11. LIFTING LOADS 11. LIFTING LOADS Never permit any persons to stand or pass under lifted load. L255OM55 Never use wire rope to lift a load. L255OM56...

  • Page 33: Know Your Truck

    3. KNOW YOUR TRUCK 3. KNOW YOUR TRUCK 1. GENERAL LOCATIONS 1. GENERAL LOCATIONS L255OM57 Turn signal lamp Carriage 13 Operator's seat Head lamp Forks 14 Counterweight Mast Overhead guard 15 Bonnet Lift chain 10 LPG tank 16 Rear wheel Lift cylinder 11 Rear working lamp(Option) 17 Tilt cylinder...

  • Page 34: Data/Safety Plates And Decals

    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)
  • Page 35 OPERATOR SAFETY WARNING DECAL OPERATOR SAFETY WARNING DECAL 2) 2) Read the manual Buckle up! Apply brake when leaving truck Watch Out For Other People Most lift truck INJURIES are to other people near the lift truck Prevent Overturns! D35AOM59 Safety and warning decals are placed in conspicuous locations on the truck Safety and warning decals are placed in conspicuous locations on the truck AVOID:...
  • Page 36 Mast warning decal Mast warning decal This safety decal is placed on the mast to warn of the danger of injury from movement between rails, chains, sheaves, fork carriage, and other parts of the mast assembly. Do not climb on or reach into the mast.

  • Page 37: Instruments And Controls

    3. INSTRUMENTS AND CONTROLS 3. INSTRUMENTS AND CONTROLS 1) 1) HLF15/18-5 HLF15/18-5 15 16 17 18 6 7 8 9 10 11 20 21 22 23 DETAIL A L155OM64 Water temperature gauge 11 Working lamp(Option) 20 Malfunction indicator Left turn signal lamp 12 Parking brake lever lamp Hour meter...
  • Page 38 2) 2) HLF20/25/30-5 HLF20/25/30-5 15 16 17 18 6 7 8 9 10 11 20 21 22 23 DETAIL A L255OM111 Water temperature gauge 11 Working lamp(Option) 20 Malfunction indicator Left turn signal lamp 12 Parking brake lever lamp(Tier 2 only) Hour meter 13 Forward-Reverse lever 21 Rear working lamp...
  • Page 39 3) 3) HLF15/18C-5, HLF20/25/30C-5 HLF15/18C-5, HLF20/25/30C-5 16 17 18 19 20 21 22 6 7 8 9 10 11 L255OM64 Water temperature gauge 11 Working lamp(Option) 20 Malfunction Left turn signal lamp 12 Parking brake lever indicator lamp Hour meter 13 Forward-Reverse lever 21 Rear working lamp Right turn signal lamp...

  • Page 40: Indicator Symbols

    4. INDICATOR SYMBOLS 4. INDICATOR SYMBOLS 1) 1) FUEL GAUGE FUEL GAUGE E : Empty F : Full Fill LPG tank regularly. Never allow machine to run out LPG. ※ Do not overfill the LPG tank. Always check the fuel level on level ground. L255OM76 ※...
  • Page 41 5) 5) ENGINE OIL PRESSURE WARNING LAMP ENGINE OIL PRESSURE WARNING LAMP This lamp informs the operator that the engine oil pressure is below the specified level. This lamp lights when starting switch is turned ON and goes out when oil pressure becomes normal. ※...
  • Page 42 Once the engine is in start or run mode, the lamp should go off. run mode, the lamp should go off. ※ Consult a Hyundai dealer to investigate the cause. Consult a Hyundai dealer to investigate the cause. 3-10...

  • Page 43: Operating Lever And Switch

    5. OPERATING LEVER AND SWITCH 5. OPERATING LEVER AND SWITCH 1) 1) START SWITCH START SWITCH There are three positions, OFF, ON and START. There are three positions, OFF, ON and START. ※ Before starting, set gear shift lever at N, and pull parking Before starting, set gear shift lever at N, and pull parking brake.
  • Page 44 5) 5) HAZARD SWITCH(OPTION) HAZARD SWITCH(OPTION) Use for parking, or loading machine. ※ If the switch is left ON for a long time, the battery may be If the switch is left ON for a long time, the battery may be discharged.
  • Page 45 PARKING BRAKE LEVER PARKING BRAKE LEVER (1) (1) Position 1 Position 1 Parking brake is applied and front wheel is locked. (2) (2) Position 2 Position 2 Parking brake is released. ※ ※ Before moving the truck be sure the parking brake is Before moving the truck be sure the parking brake is released.
  • Page 46 STEERING WHEEL LOCK KNOB STEERING WHEEL LOCK KNOB The angle of the steering shell can be adjusted forward and Lock backward. ① Release Release : Turn the knob down. ② Lock Lock : Turn the knob up. Release L255OM91 ※ METHOD OF ADJUSTING STEERING WHEEL ANGLE METHOD OF ADJUSTING STEERING WHEEL ANGLE Turn the lock knob down.
  • Page 47 SEAT ADJUSTMENT SEAT ADJUSTMENT The seat adjustable to fit the contours of the operator's body. It will reduce operator fatigue due to long works hours and enhance work efficiency. (1) (1) Forward/Backward adjustment (A) Forward/Backward adjustment (A) ① Pull lever A to adjust seat forward or backward. ②...

  • Page 48: Fuel System

    6. FUEL SYSTEM 6. FUEL SYSTEM Shut off valve Hose Gauge Locator pin Relief valve D35AOM105 LPG is HIGHLY FLAMMABLE. Never smoke when changing tanks. Never change tanks with the LPG is HIGHLY FLAMMABLE. Never smoke when changing tanks. Never change tanks with the engine running.

  • Page 49: 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 and Do not operate a truck if it is in need of repair.
  • Page 50 FUNCTIONAL CHECKS FUNCTIONAL CHECKS 2) 2) 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 51: Refueling Lpg Tanks

    2. REFUELING LPG TANKS 2. REFUELING LPG TANKS When changing liquefied petroleum gas(LPG), When changing liquefied petroleum gas(LPG), tanks follow these basic rules; tanks follow these basic rules; ① Change only in well ventilated areas. ② Never allow open flames. ③...
  • Page 52 3) 3) RECOMMENDED SAFETY MAINTENANCE PROCEDURES FOR LPG-FUELED LIFT TRUCKS RECOMMENDED SAFETY MAINTENANCE PROCEDURES FOR LPG-FUELED LIFT TRUCKS LPG is a combustible fuel that is heavier than air. Escaping gas may accumulate in low areas. The fuel cylinder should be mounted so that it does not extend outside the truck and should also be properly positioned by using the locating pin or key way.

  • Page 53: Starting And Operating Procedures

    5. STARTING AND OPERATING PROCEDURES 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. Safe operation is the responsibility of the operator.

  • Page 54: Check Before Starting

    2. CHECK BEFORE STARTING 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 55: 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 overhead guard, backrest and forks for crack or obvious damage.
  • Page 56 CHECK BRAKE FLUID Remove reservoir cap, and check level. If necessary, add brake fluid. Normal Fluid : DOT 3 (SAE J1703e) 25-45 mm (1-1.8 in) D35AOM110 CHECK COOLANT LEVEL If the cooling water in the radiator sub-tank is not within normal range when cool, add water to the MAX line.
  • Page 57 When engine oil pressure warning lamp(1) or battery charge warning lamp(2) turns on, add engine oil or distilled water respectively. L255OM40 CHECK PARKING BRAKE If the operating force is below 20-30kg (44-66 lb), contact your 20-30 kg Operating HYUNDAI forklift distributor. (44-66 lb) force...
  • Page 58 CHECK HORN AND LAMPS Check horn button and lamp switch if operate normally or not. 1 : Horn button 1' : Lamp switch If horn and lamp are malfunctioning, contact your HYUNDAI forklift distributor. D255OM13 CHECK PEDALS Check for any catching or abnormal heaviness when depressing the pedals.

  • Page 59: Seat Adjustment

    4. SEAT ADJUSTMENT SEAT ADJUSTMENT The seat adjustable to fit the contours of the operator's body. It will reduce operator fatigue due to long works hours and enhance work efficiency. Forward/Backward adjustment(A) Pull lever A to adjust seat forward or back ward. The seat can be moved forward and backward over 12mm in 10steps.

  • Page 60: Starting From A Safe Condition

    5. STARTING FROM A SAFE CONDITION Always start from a safe condition. Before operating a lift truck, make sure that : You are safely seated in the truck. The parking brake is applied. The forks are fully lowered to the floor or ground.

  • Page 61: 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 directional control in NEUTRAL, the seat adjusted, and your seat belt buckled. INSPECT YOUR LIFT TRUCK BEFORE OPERATING at the start of each shift.

  • Page 62: Starting The Engine

    7 7 . STARTING THE ENGINE START FROM A SAFE CONDITION Before you start the truck, safely seat yourself on the truck, fasten seat belt, apply the parking brake, make sure all controls are in neutral or other correct position, lower the forks fully to floor or ground, put the direction control lever in NEUTRAL, and make sure you know how to operate the truck and all its controls.

  • Page 63: Check After Starting Engine

    8. CHECK AFTER STARTING ENGINE CHECK FOR ABNORMAL NOISE OR VIBRATION CHECK ENGINE EXHAUST COLOR Exhaust gas color Criteria Colorless, light blue Black Check for incomplete combustion White Check for oil leakage CHECK FUEL TANK LEVEL If the indicator points to F, the tank is full. If the indicator enters the E range, refill the fuel tank immediately.
  • Page 64 CHECK LIFT CHAIN TENSION Raise forks 10 to 15cm(4 to 6in) from ground. Push with a rod check that both chains have approximately same amount of slack. Adjusting lift chain Loosen locknut and turn nut. Equalize tension on the lift chain. o not put hands into the mast.

  • Page 65: Levers And Pedals

    9. LEVERS AND PEDALS 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 (forks) 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 66 Selecting direction of travel Push the direction control lever forward, center it , or pull it back Directional control for FORWARD, NEUTRAL, or REVERSE, respectively. lever Traction is disabled in NEUTRAL. L255OM65 Using the accelerator pedal With the parking brake released and the direction control in FORWARD or REVERSE, put your foot on the accelerator pedal and push down smoothly until the truck is moving at the desired speed.

  • Page 67: Operating Safely

    10. OPERATING SAFELY Safe operation is the responsibility of the operator. WATCH WHERE YOU ARE GOING. DON’T GO IF YOU CAN’T SEE... Before driving, check all around to be sure that your intended path of travel is clear of obstructions and pedestrians.
  • Page 68 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. GRADES, RAMPS, AND INCLINES...

  • Page 69: Load Handling

    11. LOAD HANDLING 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 70 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. To adjust the forks, raise the carriage slightly. Tilt the mast fully forward to reduce friction and make the fork slide easier.
  • Page 71 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 72 STACKING To put a load on a stack Aproach slowly and align the lift truck and load squarely with the stack. D35AOM137 Raise the load as the lift truck nears the stack. D35AOM138 Move forward slowly until the load almost touches the stack. The leading edge and sides of the load pallet should line up exactly with the near edge and side of the load or rack on which you are stacking.
  • Page 73 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 74: Shut Down Procedure

    1 1 2. SHUT DOWN PROCEDURE Always leave your lift truck in a safe condition. When you leave your truck, or park it, follow these safely rules Park in a safe area away from normal traffic. Never park on a grade. Never park in areas that block emergency routes or equipment, access to fire aisles, or stairways and fire equipment.

  • Page 75: 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 76 Park the disabled truck in authorized areas only. Fully lower the forks to the floor, put the directional control lever in the NEUTRAL position and turn the staring switch to the OFF position. Engage the parking brake. Remove the key and, when necessary, block the wheels to prevent the truck from rolling.

  • Page 77: How To Use Battery Jumper Cables

    2. HOW TO USE BATTERY JUMPER CABLES 2. 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 12V, negative-ground electrical system. The "Booster" battery must be fully charged and in good condition.
  • Page 78 Connect the jumper cables in the following To ground sequence: To start switch Charged battery ⓐ Connect a jumper cable from the positive(+; red) terminal on one battery to the positive(+; red) terminal on the other battery. Never connect positive(+; red) to negative(-;...

  • Page 79: Planned Maintenance And Lubrication

    Specifications for selected components, fuel, lubricants, critical bolt torques, refill capacities, and settings for the truck and found in section 9. If you have needed for more information on the care and repair of your truck, see your HYUNDAI dealer.

  • Page 80: 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 81 Before leaving the truck. Stop the truck. Fully lower the load-engaging means: mast, carriage, forks or attachments. Put the directional control in NEUTRAL. Apply the parking brake. Stop the engine. Turn the key switch to the OFF position. Put blocks at the wheels if the truck must be left on an incline. Brakes, steering mechanisms, control mechanisms, warning devices, lights, governors, lift overload devices, lift and tilt mechanisms, articulating axle stops, load backrest, overhead guard and frame members must be carefully and regularly inspected and maintained in a safe operating condition.
  • Page 82 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 83: Major Component Locations

    3. MAJOR COMPONENT LOCATIONS 9 10 L255OM23 Mast Transmission 15 Muffler Lift cylinder Torque converter 16 Counterweight Tilt cylinder 10 Engine 17 Radiator Control valve 11 Rear wheel 18 Overhead guard Fork 12 Steering axle(Rear) 19 Operator's seat Front wheel 13 Steering cylinder 20 Air cleaner Drive axle...

  • Page 84: Periodic Replacement Of Consumable Parts

    4. PERIODIC REPLACEMENT OF CONSUMABLE PARTS For operation safety, never fail to perform periodic maintenance or make periodic replacement of the consumable parts listed below. These parts may deteriorate in time and are susceptible to wear. It is difficult to estimate the degrees of wear at time of periodic maintenance;...

  • Page 85: Planned Maintenance Intervals

    5. PLANNED MAINTENANCE INTERVALS Time intervals between maintenances are largely determined by operating conditions. For example, operation in sandy, dusty locations requires shorter maintenance intervals than operation in clean ware-houses. The indicated intervals are intended for normal operation. The operating condition classifications are.
  • Page 86 The maintenance time intervals referred to in this manual relate to truck operating hours as recorded on the hour meter, and are based on experience HYUNDAI has found to be convenient and suitable under typical(Normal or average) operating conditions. The periods and their designations are:...
  • Page 87 Daily maintenance checks Check truck for obvious damage and leaks. Check fuel system for leaks, etc.. Check capacity, warning plates and decals. Check condition of tires and wheels. Remove embedded objects. Check air pressure. Check for missing or loose wheel lug nuts. Check engine oil level.

  • Page 88: How To Perform Planned Maintenance

    6. HOW TO PERFORM PLANNED MAINTENANCE 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. Check to be sure all capacity, safety, and warning plates are attached and legible.
  • Page 89 FORKS Inspect the load forks for cracks, breaks, bending, and wear. The fork top surfaces should be level 10% of "A" is and even with each other. The height difference max wear allowed between both fork tips should be no more than 3% of the fork length.

  • Page 90: Replacement

    7. REPLACEMENT 7. REPLACEMENT BATTERIES EMIT EXPLOSIVE GAS. Do not BATTERIES EMIT EXPLOSIVE GAS. Do not smoke or have open flames or sparks in battery smoke or have open flames or sparks in battery charging areas or near batteries. An explosion charging areas or near batteries.
  • Page 91 Prior to reinstall the cable, inspect in detail and Prior to reinstall the cable, inspect in detail and Connect (-) lead last confirm the condition of the cables and replace confirm the condition of the cables and replace it when the cables possess any kind of it when the cables possess any kind of abnormal damages such as cracking and wear abnormal damages such as cracking and wear...
  • Page 92 (3) (3) Installation Installation When installing the element, check that the cleaner housing and element cover are completely in close contact, then tighten the nut. When using compressed air, use safety glasses, face shield and other protective clothes. Never When using compressed air, use safety glasses, face shield and other protective clothes. Never point the air nozzle at anyone.
  • Page 93 TRANSMISSION OIL Do not touch hot components or allow hot oil to contact your skin. Dipstick Transmission oil Normal Park the truck in a level place and lower the Cold forks. Then stop the engine and apply the parking brake. Oil level check Drain plug Open inspection plate, and oil level can be...
  • Page 94 HYDRAULIC TANK Hydraulic oil change Park the truck in a level place and lower the Breather forks. Then stop the engine and apply the parking brake. Change oil after removing drain plug on tank bottom. Cover Strainer Cleaning OSHA-approved eye protection rated for 200kPa(30psi) is required for air cleaning Suction strainer...
  • Page 95 The tires and rims should always be serviced or changed by trained 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.
  • Page 96 When jacking up the truck, always check carefully that the jack does not come out of position. When jacking up the truck, never go under the truck. For wheels using a separate type rim, check first that the rim nut is not loose before loosening the lug nuts.
  • Page 97 LAMP BULBS REPLACEMENT Lamp Spec(for 12V) Head lamp Turn signal lamp Stop/clearance lamp 21/5W Backup lamp Head/Feul Warning lamp Others 1.4W Meter lighting lamp 3.4W D255OM14 Beacon lamp (option) Strobe type Rear work lamp (option) After checking that the fuse is not blown and that there is no disconnection in the wiring harness, replace the lamp bulb.
  • Page 98 Indicator lights Check that all lights are functioning and indicate normal truck operation as described in section 3, Know your truck, in this manual. Service brakes and inching pedal With the direction control in NEUTRAL and the engine running, push the sevice brake pedal fully down and hold.
  • Page 99 Steering system 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 changes in steering action. Hard steering, excessive freeplay(Looseness), or unusual sound when turning or maneuvering indicates a need for inspection or servicing.
  • Page 100 Inspect the battery for damage, cracks, leaking condition, etc.. If the terminals are corroded, clean and protect them with HYUNDAI battery saver(Available from your HYUNDAI dealer). If your battery has removable cell caps, check to be sure the cells are all filled. Refill them with distilled water.
  • Page 101 OIL PERFORMANCE DESIGNATION: To help achieve proper engine performance and durability, use only engine lubricating oils of the proper quality. For LPG and diesel engines, HYUNDAI recommends that you use motor oil that meets API service classification CD, CC/SG, SF and API CH4 SAE 15W-40 for diesel engines, gas engines use API SG, SAE 10W-30 oil or better.
  • Page 102 Clean the fittings and lubricate the tilt cylinder rod end bushings(forward end) and both the base rod-end bushings(rear end). Clean and lubricate the mast trunnion bushings. Lift chains Lubricate the entire length of the mast rail lift and carriage chains with HYUNDAI chain and cable lube. AIR CLEANING Always maintain a lift truck in a clean condition.
  • Page 103 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 104 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. Adjust tension on new chains.

  • Page 105: Lubrication Chart

    8. LUBRICATION CHART LIFT CHAIN DIFFERENTIAL TRANSMISSION MAST SUPPORT BRAKE FLUID HYDRAULIC RESERVOIR OIL TANK ENGINE OIL PAN LINKAGE KING PIN Check everyday Every two weeks(100 hours) Every month(250 hours) Every 3 month(600 hours) Every 6 month(1200 hours) L255OM46 NOTES : Check, add oil when needed.

  • Page 106: Greasing Point

    9. GREASING POINT Lift chain(coated with engine oil) Steering axle Fork stopper Pedal pin Tilt cylinder Mast support Adjust bolt L255OM45 7-28...

  • Page 107: Handling Machine In Extremely Hot Places

    10. HANDLING MACHINE IN EXTREMELY HOT PLACES Pay careful attention particularly to the following points when handling the machine in extremely hot places. Scale and rust form more easily in the cooling system, so wash with anticorrosion liquid. Always try to have clean and soft water circulating in the system.

  • Page 108: Cold Weather Operation

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

  • Page 109: Storage

    12. 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. When the truck has to be placed outdoors, park it on a even ground and cover it securely with canvas.

  • Page 110: Transport

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

  • Page 111: Loading And Unloading By Crane

    13A. LOADING AND UNLOADING BY CRANE Check the weight, length, width and height of the truck referring to the chapter 8, specifications Wire rope when you are going to hoist the truck. Stay Use long wire rope and stay to keep the distance To mast with the machine as it should avoid touching with the truck body.

  • Page 112: Recommendation Table For Lubricants

    14. RECOMMENDATION TABLE FOR LUBRICANTS NEW MACHINE New machine uses following fuel, coolant and lubricant. Description Specification Engine oil SAE 10W-30(API SL class or better) T/M oil ATF DEXRON III Gear oil SAE 80W-90/API GL-5 Hydraulic oil ISO VG32/VG46/VG68 Grease Lithium base grease NLGI No.2 Fuel ASTM D975-No.2...

  • Page 113: Fuel And Lubricants

    15. FUEL AND LUBRICANTS Capacity (U.S.gal) Ambient temperature Service Kind of point fluid 1.5~1.8 2.0~3.0 (-4) (14) (32) (50) (68) (86) (104) Engine oil Engine oil SAE 10W-30(API SL class or better) (2.0) Torque ATF DEXRON III converter (1.7) (2.6) Engine oil transmission Axle...

  • Page 114: Information For Lpg

    8. INFORMATION FOR LPG 1. FOREWARD 1. FOREWARD This chapter describes the method of operation of HYUNDAI FORKLIFT that is powered by LPG (Liquefied petroleum gas). This fuel is normally supplied in a gas tank and must be purchased locally by user.

  • Page 115: Lpg Device Components

    3. LPG DEVICE COMPONENTS 3. LPG DEVICE COMPONENTS Band Clamp Tank Tank bracket support Tank bracket Relief valve Tank bracket support LPG mixer and throttle body assy LPG regulator assy D35AOM178 D35AOM179 L255OM101...

  • Page 116: Lpg Tank And Related Parts

    4. LPG TANK AND RELATED PARTS 4. LPG TANK AND RELATED PARTS 1) 1) OUTFLOW VALVE OUTFLOW VALVE This valve controls the flow of LPG fuel from the LPG tank to the regulator. To open the valve, turn it counterclockwise. D35AOM182 2) 2) INFLOW VALVE...

  • Page 117: Changing The Lpg Tank

    5. CHANGING THE LPG TANK 5. CHANGING THE LPG TANK Under no circumstances what so ever may the LPG tank replacement be performed near a lighted cigarette, lighted match, gas stove burner, or any other electric appliance that emits sparks, flame or any type of fire.
  • Page 118 Turn the tank bracket backwards around the left Turn the tank bracket backwards around the left side tank bracket, and fix it with a set pin. side tank bracket, and fix it with a set pin. D35AOM188 Pull the tank bracket clamp toward you, and Pull the tank bracket clamp toward you, and unlock the band.

  • Page 119: Recommended Safety Maintenance Procedures

    6. RECOMMENDED SAFETY MAINTENANCE PROCEDURES 6. RECOMMENDED SAFETY MAINTENANCE PROCEDURES LPG is a combustible fuel that is heavier than air. LPG is a combustible fuel that is heavier than air. Escaping gas may accumulate in low areas. The fuel cylinder should be mounted so that it does Escaping gas may accumulate in low areas.

  • Page 120: Installation

    7. INSTALLATION 7. INSTALLATION Place the tank on the bracket. Align the boss of tank bracket with the hole of tank. D35AOM190 D35AOM193 Put the band on the tank, hook the clamp to the band, and push up the clamp. D35AOM194 Lift the stopper plate, then rotate the tank bracket.
  • Page 121 Turn clockwise the stopper knob located on the right side tank bracket. D35AOM196 Connect the piping to the tank out flow valve. Wet the part of the pipe that is connected to the tank with soapy water or neutral detergent, open the out flow valve and check to see that there are no gas leaks.

  • Page 122: Specifications

    9. SPECIFICATIONS 9. SPECIFICATIONS 1. SPECIFICATION TABLE 1. SPECIFICATION TABLE 1) 1) HLF15/18-5, HLF15/18C-5 HLF15/18-5, HLF15/18C-5 L255OM69 Model Unit HLF 15-5 HLF 18-5 HLF 15C-5 HLF18C-5 Capacity 1500 1750 1500 1750 ← ← ← Load center Weight(Unloaded) 2760 2940 2750 2950 Lifting height ←...
  • Page 123 2) 2) HLF20/25/30-5 HLF20/25/30-5 L255OM69 Model Unit HLF20-5 HLF25-5 HLF30-5 Capacity 2000 2500 3000 Load center ← ← Weight(Unloaded) 3560 3860 4325 Lifting height ← ← 3300 ← ← Free lift 640/570(650/580 ★ ) 640/560(650/570 ★ ) 550/470(600/500 ★ ) Fork Lifting speed(Unload/Load) mm/sec...
  • Page 124 3) 3) HLF20/25/30C-5 HLF20/25/30C-5 L255OM69 Model Unit HLF20C-5 HLF25C-5 HLF30C-5 Capacity 2000 2500 3000 ← ← Load center Weight(Unloaded) 3491 3871 4372 Lifting height ← ← 3300 Free lift ← ← Fork Lifting speed(Unload/Load) mm/sec 650/580 650/570 600/500 ← Lowering speed(Unload/Load) ←...

  • Page 125: Specification For Major Components

    2. SPECIFICATION FOR MAJOR COMPONENTS 2. SPECIFICATION FOR MAJOR COMPONENTS 1) 1) HLF15/18-5, HLF15/18C-5 HLF15/18-5, HLF15/18C-5 ENGINE ENGINE (1) (1) ITEM UNIT SPECIFICATION Model MITSUBISHI 4G63-32HL Type 4-cycle, Overhead camshaft Cooling Method Water cooled Number of cylinders and arrangement 4 cylinders, Hemisphere Firing order 1-3-4-2 Cylinder bore X stroke...
  • Page 126 (4) (4) POWER TRAIN DEVICES POWER TRAIN DEVICES Specification Item HLF15/18-5 HLF15/18C-5 Model 280-D1(KOREA POWERTRAIN) Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio Type Power shift Gear shift(FR/RR) Transmission Adjustment Electrical single lever type, kick-down system 11.278 : 1 13.720 : 1 Overhaul ratio 11.582 : 1...
  • Page 127 2) 2) HLF20/25/30-5 HLF20/25/30-5 ENGINE ENGINE (1) (1) ITEM UNIT SPECIFICATION MITSUBISHI 4G64-33HL(4G64-32HL ★ ) Model Type 4-cycle, Overhead camshaft Cooling Method Water cooled Number of cylinders and arrangement 4 cylinders, Hemisphere Firing order 1-3-4-2 Cylinder bore X stroke mm(in) 86.5×100(3.4×3.9) Piston displacement cc(cu in)
  • Page 128 (4) (4) POWER TRAIN DEVICES POWER TRAIN DEVICES Item Specification Model 280-D1(KOREA POWERTRAIN) Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio Type Power shift Gear shift(FR/RR) Transmission Adjustment Electrical single lever type, kick-down system 16.028 : 1 Overhaul ratio 18.317 : 1 Type...
  • Page 129 3) 3) HLF20/25/30C-5 HLF20/25/30C-5 ENGINE ENGINE (1) (1) ITEM UNIT SPECIFICATION Model MITSUBISHI 4G64-33HL Type 4-cycle, Overhead camshaft Cooling Method Water cooled Number of cylinders and arrangement 4 cylinders, Hemisphere Firing order 1-3-4-2 Cylinder bore X stroke mm(in) 86.5×100(3.4×3.9) Piston displacement cc(cu in) 2350(143.6) Compression ratio...
  • Page 130 (4) (4) POWER TRAIN DEVICES POWER TRAIN DEVICES Item Specification Model 280-D1(KOREA POWERTRAIN) Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio Type Power shift Gear shift(FR/RR) Transmission Adjustment Electrical single lever type, kick-down system 16.028 : 1 Overhaul ratio 18.317 : 1 Type...

  • Page 131: Tightening Torque

    3. TIGHTENING TORQUE 3. TIGHTENING TORQUE 1) 1) HLF15/18-5 HLF15/18-5 kgf·m lbf·ft ITEMS SIZE M16×2.0 Engine mounting bolt, nut Engine M 8×1.25 Radiator mounting bolt, nut 2.5±0.5 18.1±3.6 M 8×1.25 Torque converter mounting bolt 2.8±0.2 20.3±1.4 Hydraulic M10×1.5 MCV mounting bolt, nut 6.9±1.4 50±10 system...
  • Page 132 3) 3) HLF20/25/30-5 HLF20/25/30-5 kgf·m lbf·ft ITEMS SIZE M16×2.0 Engine mounting bolt, nut Engine M 8×1.25 Radiator mounting bolt, nut 2.5±0.5 18.1±3.6 M 8×1.25 Torque converter mounting bolt 3.4±0.7 24.6±5.1 Hydraulic M10×1.5 MCV mounting bolt, nut 6.9±1.4 50±10 system M10×1.5 Steering unit mounting bolt 6.9±1.4 50±10...

  • Page 133: Troubleshooting

    10 . TROUBLESHOOTING 10 . TROUBLESHOOTING 1. ENGINE SYSTEM 1. ENGINE SYSTEM Trouble symptom Trouble symptom Probable cause Probable cause Remedy Remedy ·Low oil level in oil pan. ·Add oil. Oil pressure warning lamp ·Oil filter element clogged. ·Replace element. fails to go out.

  • Page 134: Electrical System

    2. ELECTRICAL SYSTEM 2. ELECTRICAL SYSTEM Trouble symptom Trouble symptom Probable cause Probable cause Remedy 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.

  • Page 135: Torque Flow System

    3. TORQUE FLOW SYSTEM 3. TORQUE FLOW SYSTEM Trouble symptom Trouble symptom Probable cause Probable cause Remedy Remedy 1. Excessive oil temperature 1. Excessive oil temperature ·Improper oil level. ·Check oil level. Add or drain oil as rise rise 1) Torque converter necessary.
  • Page 136 Trouble symptom Trouble symptom Probable cause Probable cause Remedy Remedy 3. Low output power 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.
  • Page 137 Trouble symptom Trouble symptom Probable cause Probable cause Remedy Remedy 4. Unusual oil pressure 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.
  • Page 138 Trouble symptom Trouble symptom Probable cause Probable cause Remedy Remedy ·Foreign matter intruding into oil pass- ·Disassemble, check and repair or 6. Power is not transmitted 6. Power is not transmitted (Continue) age to clutch. replace. ·Shaft spline worn. ·Disassemble, check and replace. ·Oil leaks from oil seal.

  • Page 139: Steering System

    4. STEERING SYSTEM 4. STEERING SYSTEM Trouble symptom Trouble symptom Probable cause Probable cause Remedy 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.

  • Page 140: Brake System

    5. BRAKE SYSTEM 5. BRAKE SYSTEM Trouble symptom Trouble symptom Probable cause Probable cause Remedy Remedy ·Hydraulic system leaks oil. ·Repair and add oil. 1. Insufficient braking force ·Hydraulic system leaks air. ·Bleed air. ·Lining surface soiled with water or oil. ·Clean or replace.
  • Page 141 Trouble symptom Trouble symptom Probable cause Probable cause Remedy Remedy ·Lining poor contact with drum. ·Repair or replace. 6. Brake squeaks ·Anti-rattle spring poorly installed. ·Repair or replace. (continue) ·Drum sliding surface roughened. ·Repair by polishing or replace. 7. Brake rapping ·Drum eccentric or excessively distort- ·Replace.

  • Page 142: Hydraulic System

    6. HYDRAULIC SYSTEM 6. HYDRAULIC SYSTEM Trouble symptom Trouble symptom Probable cause Probable cause Remedy 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.

  • Page 143: Testing And Adjusting

    11. TESTING AND ADJUSTING 11. TESTING AND ADJUSTING 1. ENGINE SYSTEM 1. ENGINE SYSTEM EASE OF STARTING, NOISE EASE OF STARTING, NOISE Set gear shift lever at N, and pull parking brake. Turn key to START, and start engine. When engine starts, check if it starts smoothly, and if it makes any abnormal noise.
  • Page 144 RADIATOR CAP RADIATOR CAP Push pressure regulator spring with finger and check that tension is correct(①). Pull negative pressure valve, and check that it is closed when released(②). If packing is damaged, replace whole radiator cap assembly. L255OM92 ENGINE OIL ENGINE OIL Check oil level with dipstick and add oil if necessary.
  • Page 145 FAN BELT FAN BELT Check that fan belt is not damaged. Check inside of belt also. If bottom of pulley groove is shining, belt will slip so replace. Check deflection when fan belt is pushed with a finger pressure 4.5kg at a point midway between fan pulley and alternator pulley.

  • Page 146: Drive System

    2. DRIVE SYSTEM 2. DRIVE SYSTEM GEAR SHIFT LEVER GEAR SHIFT LEVER Check that there is no play when gear shift lever is at neutral. Check that gear shift lever moves smoothly to travel position and that there is no play at travel position.
  • Page 147 · HLF20/25/30C-5 HLF20/25/30C-5 ① Adjust stopper bolt(1) so that pedal 10~15mm height is 140~150mm. 140~150mm ② Adjust rod(2) so that pedal play is 10~15mm. L255OM70 Inching pedal Inching pedal · HLF15/18-5 HLF15/18-5 Inching pedal ① Adjust stopper bolt(1) so that pedal Brake pedal height is 132~142mm.
  • Page 148 · HLF20/25/30C-5 HLF20/25/30C-5 Inching pedal ① Adjust stopper bolt(1) so that pedal 20~30mm Brake pedal 140~150mm height is 140~150mm. Inching pedal interconnection ② Adjust rod(2) so that length of inching spool is 33mm when pedal height is 140~150mm. ③ Adjust bolt(3) so that brake pedal interconnects with inching pedal at inching pedal stroke 20~30mm.

  • Page 149: Travel System

    3. TRAVEL SYSTEM 3. TRAVEL SYSTEM TIRES TIRES Check tire pressure using tire gauge : SEE 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 Wear Measure tread of pneumatic tires(tires...

  • Page 150: Steering System

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

  • Page 151: Adjustment Of Parking Brake Lever

    5. ADJUSTMENT OF PARKING BRAKE LEVER 5. ADJUSTMENT OF PARKING BRAKE LEVER Put the lever in the brake released position. Pull the lever toward you as far as the Knob length of the play. Hold pin(1) with your fingers to prevent it from coming out.

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