Table of Contents

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Introduction - - - -- - -- - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - - -- 0-2
How to use this manual - - - - -- - - - - - - - - - -- - - - - - - - - - -- - - - - - - 0-3
Safety label - - - -- - -- - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - - -- 0-5
Guides on use - - - - - - - - - - -- - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - - -- - - 0-12
Integrated call center - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - - -- - - - - - 0-14
Sales distributors - - - - - - - - - -- - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - -- - 0-15
Authorized service shops - - - - -- - - - - - - - - - - -- - - - - - - - - - -- - - 0-16
Parts distributors - - - - - -- - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - - -- - - - 0-17
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
11. Tip over - -- - -- - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - - -- - - - - - - - - - -- - 1-12
12. Surface and capacity -- - - - - - - - - - - -- - - - - - - - - - -- - - - - - - 1-14
13. Parking - -- - - - - - - - -- - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - - -- - - - - - - - - 1-15
14. Lifting, jack-up and blocking - - - - - - - - - - - -- - - - -- - - 1-16
15. Lifting of forklift truck - - - - - - - - - - -- - - - - - - - - - -- - - - - - -- - - 1-21
16. Side shift and fork positioner (optional) - - - - - 1-22
1. Loose loads - - - - - - - -- - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - - --- - 2-1
2. Long and wide loads - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - - 2-2
3. Rear swing - - - - - - - - - - -- - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - -- - 2-2
4. Low overhead clearance - - - - - - - - - - -- - - - - - - - - - --- - 2-3
5. Fast turns and high loads - - - - - - - -- - - - - - - - - - -- -- - - 2-3
6. Drop-offs - - - - - - -- - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - 2-4
7. Right angle stacking - -- - - - - - - - - - -- - - - - - - - - - - -- - - - - - - 2-4
8. Chain slack - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - - -- - - - - - - - - -- -- 2-5
9. Pallets and skids -- - - - - - - - - - -- - - - - - - - - - - -- - - - - - - - - - -- - - 2-5
10. Caution for electrical lines - - - - - - - - -- - - - - - - - - - --- - 2-6
11. Solid tire --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- -- - 2-7
12. Weight indicator (option) -- -- -- --- -- -- -- -- --- -- -- - 2-7
1. General locations -- -- --- -- -- -- -- --- -- -- -- -- -- --- -- -- -- 3-1
2. Name plate -- -- -- -- -- --- -- -- -- -- -- --- -- -- -- -- --- -- -- -- -- -- 3-2
3. Cab devices - -- -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- -- 3-3
4. Cluster - --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- -- --- -- -- - 3-4
5. Switches and levers -- -- -- -- --- -- -- -- -- --- -- -- -- -- -- - 3-12
6. Cab control devices - -- -- -- -- --- -- -- -- -- --- -- -- -- -- -- 3-18
7. Battery cover - -- -- --- -- -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- - 3-19
1. Daily safety inspection -- -- -- -- --- -- -- -- -- --- -- -- -- - 4-1
2. Apparent shape inspection - --- -- -- -- -- --- -- -- -- 4-2
3. Function inspection --- -- -- -- -- --- -- -- -- -- -- --- -- -- -- - 4-3
4. Actions on inspection results -- -- -- -- --- -- -- -- - 4-3
5. 5. STARTING AND OPERATING PROCEDURES
STARTING AND OPERATING PROCEDURES
1. Before operating the truck - -- -- -- -- --- -- -- -- -- --- 5-1
2. Starting from a safe condition - -- -- --- -- -- -- -- - 5-1
3. Traveling of the truck - -- -- --- -- -- -- -- -- --- -- -- -- -- -- 5-2
4. Speed adjusting --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- - 5-4
5. Brake operation - -- -- -- -- --- -- -- -- -- -- --- -- -- -- -- --- -- -- 5-4
6. Plugging -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- 5-4
7. Operating safely - -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- -- -- - 5-5
8. Load handling -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- -- 5-7
9. Shut down procedure -- -- -- -- --- -- -- -- -- -- --- -- -- -- 5-13
1. Hauling - -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- - 6-1
2. Emergency mast lowering - -- -- --- -- -- -- -- --- -- - 6-3
7. 7.
1. Introduction --- -- -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- - 7-1
2. Safe maintenance practices -- --- -- -- -- -- --- -- - 7-2
3. Basics - -- --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- -- --- -- -- 7-4
4. Parts positions - -- -- -- --- -- -- -- -- -- --- -- -- -- -- --- -- -- -- -- 7-7
CONTENTS
CONTENTS

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Summary of Contents for Hyundai 25B-X

  • Page 1: Table Of Contents

    CONTENTS CONTENTS A message to hyundai lift truck operators --- - 0-1 11. Solid tire --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- -- -- -- --- -- -- - 2-7 Introduction - - - -- - -- - - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - -- - - - - - - - - - - -- 0-2 12.
  • Page 2 5. Regular maintenance ------------------------------- 7-9 6. Planned maintenance intervals --------------- 7-10 7. How to perform planned maintenance --- 7-11 8. Apparent shape inspection ---------------------- 7-15 9. Exchange of lubricant and consumables ---- 7-18 10. Torque inspection ------------------------------------- 7-20 11. Air cleaning ----------------------------------------------- 7-20 12.
  • Page 3: 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.
  • Page 4: 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 5: 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, with- HYUNDAI reserves the right to make improvements and changes in specifications or design, with- out notice and without incurring obligation.
  • Page 6 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 7: Safety Label

    12 Battery handling caution 24 Fork positioner (fingertip) Model name 13 Safety instructions 27 F&R transfer (fingertip) Safety warning 14 Hook 28 HYUNDAI logo Hauling 15 Temperature 29 Fire extinguisher Mast warning 16 Brake oil 30 Lithium ion battery (opt)
  • Page 8 2. DESCRIPTION 2. DESCRIPTION There are several specific warning labels on this truck. Please become familiarized with all warning labels. Replace any safety label that is damaged, or missing. 1) 1) SAFETY WARNING SAFETY WARNING (item 3) This warning label is positioned on the inside of the upper left side of overhead guard.
  • Page 9 HAULING HAULING (item 4) This warning label is positioned on the left side of the counterweight. Please see Page 1-21 of the manual for Please see Page 1-21 of the manual for safe hauling. safe hauling. 9YBD-00120 MAST WARNING MAST WARNING (item 5) This warning label is positioned on the both side of the mast.
  • Page 10 5) 5) PARKING WARNING PARKING WARNING (item 8) This warning and caution plate are located on the right side of the dashboard. Warnings before leaving the operator seat. Be sure to lower the attachment to the ① ground. 92FH-00342 Apply the parking brake. ②...
  • Page 11 SAFETY INSTRUCTION SAFETY INSTRUCTION (item 13) This warning label is positioned on the outer right side of the dashboard. FOR SAFETY 1. BEFORE OPERATING THE TRUCK, PLEASE CHECK BRAKES, STEERING SYSTEM, HORNS AND OTHER DEVICES FOR SAFETY AND MAKING IT EASY OPERATION. 2.
  • Page 12 BRAKE OIL BRAKE OIL (item 16) This label is positioned on the left side of the dashboard. Use ISO VG32 or Azolla Z32 only for brake Use ISO VG32 or Azolla Z32 only for brake oil. oil. ISO VG 32 92HN-00881 92AF-00320 HYDRUALIC OIL...
  • Page 13 SOLID TIRE SOLID TIRE (item 43) This decal is positioned on the right side of Please avoid excessive driving when 'Solid tires' are equipped. (Please refer to the operator's manual for details.) the dashboard. 97HN-00910 Do not travel at excessively high speed with Do not travel at excessively high speed with 97HN-00910 the solid tires are installed.
  • Page 14 GUIDE GUIDE 1. DIRECTION 1. DIRECTION The directions of this truck indicate forward, back- Front Front ward, right and left when truck is in the traveling direction. Left Right Left Right Rear Rear 25BX0SL02 2. SERIAL NUMBER 2. SERIAL NUMBER Inform following when you order parts or the truck is out of order.
  • Page 15 4. VIBRATION ON WHOLE BODY 4. VIBRATION ON WHOLE BODY The vibration level on the whole truck body is measured in accordance with EN13059 standards that contains in-depth testing criteria (e.g., load, speed, and road surface conditions). Vibration level at work- place may vary dependent upon actual work and surface conditions.
  • Page 16: Safety Hints

    CHAPTER1 SAFETY HINTS CHAPTER1 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 17: Do's And Don'ts

    2. DO'S AND DON'TS 2. DO'S AND DON'TS Do watch for pedestrians. 25B9UOM0102 Do wear safety equipment when required. 25B9UOM0103 Don't mix drugs or alcohol with your job. 25B9UOM0104 Don't block safety or emergency equipment. 25B9UOM0105 Don't smoke in NO SMOKING areas or when refueling. 25B9UOM0106...
  • Page 18 25B9UOM0110 Unauthorized modification Unauthorized modification Modifying the truck without authorization of the company may cause safety accident. Contact the dealer of Hyundai before attempting modifying the truck. Hyundai should not be responsible any injury or damage caused by unauthorized modification.
  • Page 19: Seat Belts

    3. SEAT BELTS 3. SEAT BELTS Always buckle up for the truck equipped with Always buckle up for the truck equipped with safety belt. safety belt. 25B9UOM0111 Seat belts can reduce injuries. Seat belts can reduce injuries. 25B9UOM0112...
  • Page 20: No Riders

    4. NO RIDERS 4. NO RIDERS The operator is the only one who should be on a truck. No riders other than operator No riders other than operator Any rider other than operator may be struck by object, or fell down off the truck. 25BX1SH02 Never let anyone step on the forks.
  • Page 21: 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. 25BX1SH04 Watch for people in your work area even if your truck has warning lights or alarms.
  • Page 22: Operator Protection

    6. OPERATOR PROTECTION 6. OPERATOR PROTECTION Keep yourself under the overhead guard while operating. Always keep your body on the seat within the confines of the truck. 25BX1SH06...
  • Page 23: Fork Safety

    7. FORK SAFETY 7. FORK SAFETY Never allow anyone to walk under raised forks. 25B9UOM0119 Do not use the folks of the truck as an eleva- tor for work at high place. 25BX1SH03...
  • Page 24: Pinch Points

    8. PINCH POINTS 8. PINCH POINTS Keep hands, feet and legs out of the mast. Keep hands, feet and legs out of the mast. 25B9UOM0121 Don't use the mast as a ladder. Don't use the mast as a ladder. 25BX1SH07 Never try to repair the mast, carriage, or Never try to repair the mast, carriage, or attachment by yourself.
  • Page 25: 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 truck is Never lift or lower the load when the truck is in motion.
  • Page 26: 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. 1) 1) Unloaded Unloaded Forks downgrade 25BX1SH12 2) 2) Loaded Loaded Forks upgrade 25BX1SH13...
  • Page 27: Tip Over

    11. TIP OVER 11. TIP OVER LATERAL TIP OVER LATERAL TIP OVER Lateral tip over can occur with a combina- tion 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.
  • Page 28 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 f your If your truck starts to tip over, do not f your truck starts to tip over, do not jump off the truck starts to tip over, do not jump off the truck.
  • Page 29: 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 the Especially when using elevators, know the capacity of the elevator you intend to to...
  • Page 30: Parking

    13. PARKING 13. PARKING Never park on a grade. 25BX1SH17 Always come to a complete stop before leaving the truck. Be sure the travel control is in NEUTRAL. 25BX1SH18 Lower forks fully to the floor and tilt mast forward. 25BX1SH19 Put the parking brake switch in LOCK posi- tion.
  • Page 31: Lifting, Jack-Up And Blocking

    14. LIFTING, JACK-UP AND BLOCKING 14. LIFTING, JACK-UP AND BLOCKING Lifting or jack-up of heavy equipment such as lift truck may cause risk. Pay special attention to the Lifting or jack-up of heavy equipment such as lift truck may cause risk. Pay special attention to the work.
  • Page 32 Incline the mast frontward to the largest extent. Then, driving wheel is lifted from the ground. Release the tilt lever, and turn the engine off. 25BX1SH22 Install block on the slip wheel cradle on the bottom of the frame of the rear driving wheel, or on the bottom of the driving wheel.
  • Page 33 5) 5) Lifting and fastening the mast Lifting and fastening the mast These procedures are for safe accessing to functional parts near the driving axle from the front of the truck. The figure illustrates disassembled mast 2-Layer standard mast It is not required to dismantle the forks. Carriage Part the lift truck safely.
  • Page 34 6) 6) Lifting rear of the truck Lifting rear of the truck It is possible to lift the rear of the truck by installing blocks on the center of the front or the rear steering axle, or on the center of the frame of the steering axle mount, or jacking up them. See the data plate for the weight of the truck.
  • Page 35 Install jack on the bottom of the side frame near the center of the truck. ※ Correctly install jack on the bottom of the Correctly install jack on the bottom of the main side frame. Do not install jack on the main side frame.
  • Page 36 15. LIFTING OF LIFT TRUCK 15. LIFTING OF LIFT TRUCK Check the weight, the full length, the full width, and the full height before lifting the truck. The battery should be removed before lift- The battery should be removed before lift- ing the lift truck.
  • Page 37 16. SIDE SHIFT AND PORK POSITIONER (OPT) SIDE SHIFT AND PORK POSITIONER (OPT) Do not handle loads held between porks. Do not handle loads held between porks. 25BX1SH30 Do not operate attachment or drive the Do not operate attachment or drive the truck while loads are ascended.
  • Page 38 If auxiliary device such as load table is not mounted on the forks, do not operate the side shift. Do not drive the lift truck while moving with cargo loaded on the side shift. When moving with cargo loaded on the side shift, weight imbalance may cause fall of cargo, or tip over of the lift truck.
  • Page 39 Neither load cargo on the fork positioner, nor operate the folk positioner with the fork arms kept on the ground. While operating the fork positioner, do not While operating the fork positioner, do not move the lever suddenly or fast. Cargo move the lever suddenly or fast.
  • Page 40: 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. 25BX2OH01 Center wide loads. 25BX2OH02 Stack and band loose material.
  • Page 41: Long And Wide Loads

    2. LONG AND WIDE LOADS 2. LONG AND WIDE LOADS With long or wide loads, you need more room. With long or wide loads, you need more room. So slow down and watch your clearance. So slow down and watch your clearance. When extra-long material makes it necessary to travel with the load elevated, do so with extreme care and be alert to load end-...
  • Page 42: 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 43: 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 avail- able.
  • Page 44: 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 chains Raise the forks before you move, or chains might brake might brake 25B9UOM0213 25B9UOM0214 9.
  • Page 45: Caution For Electrical Lines

    10. CAUTION FOR ELECTRICAL LINES 10. CAUTION FOR ELECTRICAL LINES When moving the truck with the mast raised, When moving the truck with the mast raised, watch out electrical lines over the truck. watch out electrical lines over the truck. The operating near the electrical lines is very The operating near the electrical lines is very dangerous.
  • Page 46: Solid Tire

    11. SOLID TIRE 11. SOLID TIRE Do not drive over 25 km/h. Do not drive over 8 km per hour. Do not drive on the road for automobiles. Do not drive on the road for automobile. (Example: Heat emitting for one hour after continuous driv- ing for two hours) The durability of the solid tire is not guaranteed with non-compliance.
  • Page 47: Know Your Truck

    3. KNOW YOUR TRUCK 3. KNOW YOUR TRUCK 1. GENERAL LOCATIONS 1. GENERAL LOCATIONS 25BX3KY01 Driving axle, tire and wheel Operator’s seat Mast Steering axle, tire and wheel Steering wheel Carriage and backrest Overhead guard Direction lever...
  • Page 48: Name Plate

    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 top of the right fender.
  • Page 49: Cab Devices

    3. CAB DEVICES 3. CAB DEVICES 1) 1) LOCATIONS AND NAMES LOCATIONS AND NAMES Beacon lamp switch (opt) Rear work lamp switch (opt) Headlight switch Cluster Lift lever Tilt lever Windshield wiper switch (opt) 3-Spool lever 4-Spool lever(opt) Forward and reverse driving lever Emergency stop switch Battery cover handle Parking brake lever...
  • Page 50: Cluster

    4. CLUSTER 4. CLUSTER 1) 1) STRUCTURE STRUCTURE There are 15 LED indicators (red, orange and green) on the cluster. LCD will indicate the operation and abnormal status of truck to the driver in order to use and maintenance. 25BX3KY03 Motor high-temperature warning lamp Brake oil warning lamp 15 Reverse driving indicator lamp...
  • Page 51 2) 2) WARNING LAMP WARNING LAMP Motor high-temperature warning lamp Motor high-temperature warning lamp Lights up when temperature of motor rises. 25BX3KY04 Controller high-temperature warning lamp Controller high-temperature warning lamp Lights up when temperature of controller rises. 25BX3KY05 Seat warning lamp Seat warning lamp Lights up when operator leaves the seat.
  • Page 52 Consumable exchange warning lamp Consumable exchange warning lamp (not in use) Warning lamp not in use 25BX3KY10 Brake oil warning lamp Brake oil warning lamp Lights up when brake oil level is low. 25BX3KY11 Battery charging warning lamp Battery charging warning lamp Lights up when battery charging voltage is low.
  • Page 53 3) 3) INDICATOR LAMP INDICATOR LAMP H power mode indicator lamp H power mode indicator lamp Lights up when Power Mod is High. 25BX3KY13 N power mode indicator lamp N power mode indicator lamp Lights up when Power Mod is Normal. 25BX3KY14 E power mode indicator lamp E power mode indicator lamp...
  • Page 54 4) 4) BUTTON BUTTON Cancel button Cancel button Press when canceling a function or to return to the previous menu. 25BX3KY19 Left/power mode button Left/power mode button ① Press when moving to menus on the left or the top. ② Press when switching between power modes (H/N/E). 25BX3KY20 Home button Home button...
  • Page 55: Main Screen

    4) 4) MAIN SCREEN MAIN SCREEN 25BX3KY24 25BX3KY25 Battery level Speed/time Speed mode Truck operation time/weight Battery level Battery level The battery level is displayed with ten bars. Each bar represents 10% of charging capacity. When the battery is discharged, the bars are extinguished one by one proportional with charged battery capacity.
  • Page 56 5) 5) MENUS MENUS Screen setting Screen setting 25BX3KY26 25BX3KY27 Unit setting Unit setting 25BX3KY28 25BX3KY29 Language setting Language setting 25BX3KY30 25BX3KY31 Hour Counter setting Hour Counter setting 25BX3KY32 25BX3KY33 Time setting Time setting 25BX3KY34 25BX3KY35 3-10...
  • Page 57 Warning sound setting Warning sound setting 25BX3KY56 25BX3KY57 Controller information Controller information 25BX3KY36 25BX3KY37 3-11...
  • Page 58: Switches And Levers

    5. SWITCHES AND LEVERS 5. SWITCHES AND LEVERS 1) 1) START SWITCH START SWITCH The switch supplies power to control circuit, and operates in sequence of OFF → ON clockwise. ·OFF : Power off ·ON : Power ON and truck got ready for operation 25B9UOM0324 2) 2) EMERGENCY STOP SWITCH...
  • Page 59: Horn Switch

    5) 5) BEACON LAMP SWITCH BEACON LAMP SWITCH (OPT) Press the switch to turn the beacon lamp on. 25B9UOM0328 6) 6) FNR AND HORN SWITCH FNR AND HORN SWITCH (OPT) ·FNR switch: (1) forward, (2) reverse ·Horn switch: The horn sounds when the button is pressed. FNR switch FNR switch Horn switch...
  • Page 60: Parking Brake Lever

    9) 9) FORWARD AND REVERSE DRIVING LEVER FORWARD AND REVERSE DRIVING LEVER The lever switches driving direction to forward or reverse. Push the lever forward to driving the truck in forward direction. Forward Forward When the lever is on neutral position, control switch is turned off.
  • Page 61: Brake Pedal

    BRAKE PEDAL BRAKE PEDAL Pressing the pedal stops the truck, and brake lamp on the rear side lights up. Pay special attention to operating the brake when mov- Pay special attention to operating the brake when mov- ing cargo. ing cargo. 25BX3KY43 STEERING WHEEL STEERING WHEEL...
  • Page 62: Tilt Lever

    TILT LEVER TILT LEVER Tilt forward Tilt forward Lever types Lever type Pushing the lever (fingertip) forward tilts the mast forward. Tilt forward Forward Tilt back Tilt back Pulling the lever (fingertip) backward tilts the mast backward. Hold Hold Tilt back Backward Releasing the lever (fingertip) stops movement of the mast.
  • Page 63: Seat Switch

    Fork positioner Fork positioner (independent type) LH fork movement LH fork movement ① Outstretching Outward Push the lever forward to move the LH fork outward. Pull the lever backward to move the LH fork inward. Puckering up Inward 25BX3KY49 RH fork movement RH fork movement ②...
  • Page 64: Operator's Seat Adjustment

    6. OPERATOR’S SEAT ADJUSTMENT 6. OPERATOR’S SEAT ADJUSTMENT It is allowed to adjust operator’s seat adequate for body of operator to reduce fatigue during driving, and enhance work efficiency. 1) 1) OPERATOR’S SEAT OPERATOR’S SEAT Front/rear adjustment Front/rear adjustment (A) Pull Pull Lever A to adjust the seat back and forth.
  • Page 65: Battery Cover

    7. BATTERY COVER 7. BATTERY COVER Hold the handle on the top of the battery cover to lift the cover for inspecting and ser- vicing the battery. Fix the steering column forward before Fix the steering column forward before ※ opening the battery cover.
  • Page 66 2) 2) ERROR CODE TYPES AND TROUBLESHOOTING ERROR CODE TYPES AND TROUBLESHOOTING (NUMBER OF BLINKS OF BLUE LAMP ON THE A/C BUTTON) Once : Compressor overheated: Check assembly conditions, and reduce air-conditioner airflow. Twice: Compressor & wire assembly defective, inverter device error: Check compressor and wire assembly, replace inverter.
  • Page 67: 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 68: Visual Checks

    2. VISUAL CHECKS 2. VISUAL CHECKS First, perform a visual inspection of the truck and its major components; ※ Walk around your lift truck and take note of obvious damage that may have been caused by operation during the last shift. Check that all capacity, safety, and warning plates or decals are attached and legible.
  • Page 69: Functional Checks

    3. FUNCTIONAL CHECKS 3. FUNCTIONAL CHECKS Check the operation of the truck as follows. Before performing these checks, familiarize yourself with the starting and operating procedures in Before performing these checks, familiarize yourself with the starting and operating procedures in ※...
  • Page 70: Before Operating The Truck

    CHAPTER 5 STARTING AND OPERATING PROCEDURES CHAPTER 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 71 3. BEFORE OPERATING THE TRUCK 3. BEFORE OPERATING THE TRUCK Check the aforementioned requirements, and make sure that the forward and reverse levers are on NEUTRAL position before operating the truck. Operator should sit on the operator’s seat before operating the truck. Release the emergency stop switch, and turn the starting switch clockwise 5 sec- onds later to ON position before starting the lift truck.
  • Page 72 3) 3) STOP AND PARKING STOP AND PARKING Release the accelerator pedal to reduce speed, and apply brake to stop the truck. 25BX3KY43 Return the forward and the reverse levers to Neutral position when parking the truck. Neutral position Natural 25BX5SO01 Fully pull the parking brake.
  • Page 73: Speed Adjustment

    4. SPEED ADJUSTMENT 4. SPEED ADJUSTMENT Position the forward or the reverse level on the forward or the reverse point, and gradually press the accelerator pedal until you achieve required speed. 5. BRAKE OPERATION 5. BRAKE OPERATION Release the accelerator pedal, and then press the brake pedal to stop the truck. Gradually and solid- ly press the brake pedal until the forklift stops.
  • Page 74: Operating Safely

    7. OPERATING SAFELY 7. OPERATING SAFELY Safe operation is the responsibility of the operator. 1) 1) WATCHWHERE YOU ARE GOING. DON’T GO IF YOU CAN’T SEE. WATCHWHERE 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 75 Travel with the fork carriage tilted back and raised only enough to fully clear the ground or obstacles. In such a case, the fork carriage should fully be inclined backward. When the carriage (load) is in an elevated position the stability of the truck is reduced. Do not elevate the load except during stacking.
  • Page 76: Load Handling

    8. LOAD HANDLING 8. 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 han- dling 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 77 2) 2) ADJUSTING THE LOAD FORKS ADJUSTING THE LOAD FORKS The load forks are adjustable on the hanger or the 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 for ensure stability.
  • Page 78 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 car- riage 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 79 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 80 7) 7) STACKING STACKING To put a load on a stack To put a load on a stack Approach slowly and align the lift truck and load squarely with ① the stack. 25B9UOM0516 Raise the load as the lift truck nears the stack. ②...
  • Page 81 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 82: Shut Down Procedure

    9. SHUT DOWN PROCEDURE 9. 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 83: Emergency Procedures

    6. EMERGENCY PROCEDURES 6. EMERGENCY PROCEDURES 1. HOW TO TOW A DISABLED TRUCK 1. HOW TO TOW A DISABLED TRUCK If your lift truck becomes disabled but it can be moved freely on its own wheels without further damage, use the following procedures to tow it safely to a repair area (Failed lift truck freely movable with its wheel).
  • Page 84 Park the disabled truck in authorized areas only. Fully lower the forks to the floor, put the gear selector lever in the NEUTRAL position and turn the starting switch to the OFF posi- tion. Apply the parking brake. Remove the start switch and, when necessary, block the wheels to prevent the truck from rolling.
  • Page 85: Emergency Mast Lowering

    2. EMERGENCY MAST LOWERING 2. EMERGENCY MAST LOWERING In case that the mast can't be lowered due to a problem in the controller, activate the emergency lowering valve on the MCV assy by rotating the valve (a). Manual override features are intended for emer- Manual override features are intended for emer- gency use, not for continuous-duty operation.
  • Page 86: Planned Maintenance And Lubrication

    Specifi cations for selected components, fuel, lubricants, critical bolt torques, refi ll 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 87: 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 88 Before leaving the truck. Before leaving the truck. Stop the truck. Fully lower the load-engaging means (mast, carriage, forks or attachment), and incline the mast forward. Put the gear selector lever in NEUTRAL. Apply the parking brake. Turn the start switch to OFF position. Put blocks at the wheels if the truck must be left on an incline.
  • Page 89 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. Since service meter is virtually identical with period, it is allowed to perform inspection and maintenance in scheduled interval.
  • Page 90: Proper Maintenance

    Reading the cluster does not fully guarantee the conditions of the truck. Perform routine mainte- nance in accordance with the specifi cs in the inspection and maintenance checklists. Ask to your local dealer or Hyundai for maintenance advise it unknown. Engine and hydraulic components have been preset in the factory.
  • Page 91 Repair or replace if an abnormality of these parts is found even before the recommend replace- ment interval. Please consult Hyundai dealer or service shop for replacement of these safety parts. Name Replacement cycle...
  • Page 92: Major Component Locations

    4. MAJOR COMPONENT LOCATIONS 4. MAJOR COMPONENT LOCATIONS See the figure below to find functional parts for planned maintenance procedures: 25BX7PM01 Mast Cluster 11 Operator’s seat Lift cylinder Frame 12 Steering wheel Carriage and backrest Steering axle 13 Overhead guard Forks Counterweight Drive axle...
  • Page 93: Service Locations

    2) 2) SERVICE LOCATIONS SERVICE LOCATIONS Lift chain Fork Mast roller Horn Lift cylinder Drive motor Mast mounting pin Relay & flasher Tilt pin Drive axle oil Front tire & wheel nut Display Lamp Accelerator & brake pedals SBR switch Brake oil Air breather Steering wheel &...
  • Page 94: Daily Maintenance Checklist

    5. DAILY MAINTENANCE CHECKLIST 5. DAILY MAINTENANCE CHECKLIST Service intervals are based on the hourmeter reading. DAILY (OR EVERY 10 HOURS) CHECK LIST Damage of truck and oil leak Cleanness of battery connector Battery electrolyte level Capacity, warming plate and decal Custer, warning lamp, hourmeter Horn operation and other alarming devices Additional safety devices (horn, and alarm lamp)
  • Page 95 Clean Hydraulic oil (5000) Harsh condition Normal condition Conventional hydraulic oil Hyundai genuine long life hydraulic oil A : Add C : Checking L : Lubrication R : Replacement T : Retightening I: Visual inspection (repair or replacement if required)
  • Page 96: How To Perform Planned Maintenance

    7. HOW TO PERFORM PLANNED MAINTENANCE 7. HOW TO PERFORM PLANNED MAINTENANCE 1) 1) BRAKE OIL MAKEUP BRAKE OIL MAKEUP Air vent Ventilation Hydraulic brake oil level is checked by viewing oil level in the reserver tank, and made up, if required. Max.
  • Page 97 4) 4) CHECKING HUB NUT CHECKING HUB NUT Security tighten the hub nut (M20). Tighten the hub nut in alternate directions for even tightening. (See the figure.) Tightening torque : 62.8±12.6 kgf·m 25B9UOM0705 5) 5) GREASE APPLYING GREASE APPLYING Wipe the surface with brush or cloth clean, and apply grease. Do not apply excessive grease.
  • Page 98: Fuse Exchange

    7) 7) DRIVE AXLE OIL LEVEL DRIVE AXLE OIL LEVEL Air vent Air vent Remove the plug from the drive axle, and Oiling plug check the oil level. Filling plug Drain plug Drain plug 25BX7PM04 8) 8) TRUCK BODY INSPECTION TRUCK BODY INSPECTION Inspect the truck body, and immediately consult with the shop for any defects, if any.
  • Page 99: Lift Chain Lubrication

    Lift chain lubrication is an important part of your maintenance program. The lift chains operate more safely and have longer life if they are regularly and correctly lubricated. 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 100: Visual Inspection

    8. VISUAL INSPECTION 8. 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 fastened and fit parts for loosening. ·Check to be sure all capacity, safety, and warning plates and decals are attached and legible. NAMEPLATES AND DECALS: Do not operate a lift truck with damage or lost decals and NAMEPLATES AND DECALS: Do not operate a lift truck with damage or lost decals and ※...
  • Page 101 5) 5) FORKS FORKS Inspect the load forks for cracks, breaks, bending, 10% of and wear. The fork top surfaces should be level "A", the and even with each other. The height difference max. wear 10% of "A" is allowed max.
  • Page 102 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 chunking out. Check all wheel lug nuts or bolts to be sure none are loose or missing.
  • Page 103 9. CHANGE OF HYDRAULIC OIL AND CONSUMABLES 9. CHANGE OF HYDRAULIC OIL AND CONSUMABLES 1) 1) CHANGE THE HYDRAULIC OIL CHANGE THE HYDRAULIC OIL Lower the forks on the ground and extend the tilt cylinder to the maximum. Flange Flange Loosen the cap and relieve the pressure in the tank.
  • Page 104 3) 3) REPLACEMENT OF AIR BREATHERE REPLACEMENT OF AIR BREATHERE ELEMENT ELEMENT Loosen the cap and relieve the pressure Air breather Air breather in the tank. Loosen the screw on the top of the air breather, and remove the cover Oiling cap Filling cap Replace the element with a new one.
  • Page 105: Air Cleaning

    10. TORQUE CHECKS 10. TORQUE CHECKS Parts in highly loaded (critical) components can quickly fail if they become loosened. Also, loose fasteners can cause damage or failure of the component. For safety, it is important that the correct torque be maintained on all critical fasteners of the components that directly support, handle, or control the load and protect the operator.
  • Page 106: Battery Maintenance

    12. BATTERY MAINTENANCE 12. BATTERY MAINTENANCE BATTERY BATTERY SERVICE SHOP AREA No smoking 25B9UOM0717 Battery charging, replacement and removing should be performed at designated battery shop only. The shop should be free of inflammable materials or combustibles. Facilities mandatory for the shop: ·Electrolyte cleaning facility ·Fire preventing and fire-fighting facility ·Facility protecting battery from systems...
  • Page 107: Battery Handling

    13. BATTERY HANDLING 13. BATTERY HANDLING Battery charging, replacement and removing should be performed at designated battery shop only. The battery shop should operate electrolyte cleaning facility, battery gas ventilation facility, and fire- preventing and fire-fighting facilities. Transportation facilities such as conveyor or crane should provided at the shop for removing and installing batteries.
  • Page 108: Battery Charging

    14. BATTERY CHARGING 14. BATTERY CHARGING Battery is automatically charge by charger. All you have to do is connecting the plug. 25B9UOM0720 1) 1) HOW TO USE CHARGER HOW TO USE CHARGER Connecting the plug and the battery connector lights up the input power lamp, and the charging indicator lamp, and charging starts few seconds later.
  • Page 109: Normal Charging

    2) 2) INSTALLATION OF CHARGER INSTALLATION OF CHARGER Installation place Installation place The charger should be installed at a place of well ventilation, low temperature/humidity, and free from dusts. Check input power the charger for adequacy with input power of distribution panel. Check grounding line of the charging cable for well grounding of the grounding line.
  • Page 110: Battery Replacement

    15. BATTERY REPLACEMENT 15. BATTERY REPLACEMENT 1) 1) GENERAL GENERAL ·Battery can be replaced by making use Top cover of lift truck, or palette truck and · Locking exclusive jigs. device ·Capacity of the lift truck for battery replacement should be 2-3 tons, and palette truck of 1.5-2 tons.
  • Page 111 Adjust the width of the forks (A) aligned with the opening of the frame floor, and mark insertion depth (B). ·25B-X width (A) : 326 mm ·30/32/35B-X width (A) : 396 mm ·Depth (B) : 830 mm Replace the battery by working in pair (operator, and signal man).
  • Page 112 2) 2) REPLACEMENT WITH PALETTE TRUCK REPLACEMENT WITH PALETTE TRUCK Prepare hand-driven palette (outer width Hand-driven of 680 mm), and exclusive jigs. palette Exclusive jig Align the exclusive jig on the center of the palette, mark jig insertion depth (B: 780 mm).
  • Page 113 Battery docking with lift truck · Use block of height of 60 mm or more (A). Battery Unit : mm Model 25B-X 30/32/35B-X Fork Block Battery width (B) Fork width (C) Block height (D)
  • Page 114 Block Fork battery replacement should be same as batteries under operation. Unit : mm 25BX7PM28 Model 25B-X 30/32/35B-X Battery width (C) Block gap (D) Outer width of fork (E) 7-29...
  • Page 115: Battery Maintenance

    16. BATTERY MAINTENANCE 16. BATTERY MAINTENANCE 1) 1) PROHIBITION OF OVER-DISCHARGE PROHIBITION OF OVER-DISCHARGE If the battery is so exhaustively consumed that the truck can not move anymore, the service life of the battery is reduced. When turning the starting switch to ON position, and the battery charging indicator bar blinks, immediately charge the battery.
  • Page 116: Lithium Ion Battery (Option)

    17. LITHIUM ION BATTERY (OPT) 17. LITHIUM ION BATTERY (OPT) 1) 1) STRUCTURE STRUCTURE Battery pack Battery pack 25BX7PM14 Housing Module Cable Top case Battery module Battery module 25BX7PM15 Module frame Eye-cut Cell PC cover +: Anode terminal, -: Cathode terminal Module bus bar 7-31...
  • Page 117: Inspection Procedures

    BMS and BPU BMS and BPU 25BX7PM16 Grounding bus bar Current sensor Relay 2) 2) INSPECTION PROCEDURES INSPECTION PROCEDURES Daily inspection before starting Daily inspection before starting Make sure that the battery pack charging terminal (DIN320 connector) is disconnected on the ·...
  • Page 118: Use And Operation

    18. LITHIUM ION BATTERY CHARGER (OPT) 18. LITHIUM ION BATTERY CHARGER (OPT) Read and understand the following instructions Read and understand the following instructions ※ before connecting battery charger to power before connecting battery charger to power source and battery. source and battery.
  • Page 119: Power Connection

    Always use special bipolar connector (DIN 320 REMA). ⑨ Do not extent existing power connection with additional cable. ⑩ The charger is free from maintenance except routine cleaning. Cleaning should be performed ⑪ regularly dependent upon working environments. Disconnect power cable and battery connection cable from power source before cleaning the charger.
  • Page 120: Storage

    19. STORAGE 19. STORAGE ※ Cautions Cautions Improper storage of the truck may cause damage and corrosion of major functional parts, or Improper storage of the truck may cause damage and corrosion of major functional parts, or damage and discharging of the battery. The battery of the lift truck should be stored in indoor damage and discharging of the battery.
  • Page 121: Lubricants For New Truck

    Lubricants and oils listed below are used on new truck for shipping. Item Specifications Gear oil ATF DEXRON 3 Hydraulic oil and steering oil ISO VG32, VG4, VG68, Hyundai’s long-life hydraulic oil ISO VG15, Hydraulic oil ★ Brake oil ISO VG10, VG32 Grease NLGI No.2...
  • Page 122: Specifications

    CHAPTER 8 SPECIFICATIONS CHAPTER 8 SPECIFICATIONS 1. SPECIFICATION TABLE 1. SPECIFICATION TABLE 25BX8SP01 Item Unit 25B-X 30B-X 32B-X 35B-X Rated load 2500 3000 3200 3500 Center of gravity ← ← ← Weight 4604 5043 5242 5486 Lifting height 3300 ←...
  • Page 123: Specification For Major Components

    Drive motor Pump motor Type ASRH4001 AMSR4001 Rated voltage Output Insulator Grade F Grade F 3) 3) BATTERY BATTERY Item Unit 25B-X 30/32/35B-X Type Plumbic acid ← Rated voltage ← Capacity AH/hr 600/5 700/5 Electrolyte ← Dimensions (W×L×H) 984×466×744 984×536×744...
  • Page 124 DC output 64±1 Charging time 6±2 Connector SB 350 or SR 350 LITHIUM ION CHARGER (OPT) LITHIUM ION CHARGER (OPT) Item Unit 25B-X 30/32/35B-X Capacity of battery for charging V-AH 51.2-500 51.2-600 AC input 3-Phase, 400 ← DC output 58.8 ←...
  • Page 125 7) 7) DRIVE AXLE DRIVE AXLE Item Unit Specifications Max. axle load 9000 Max. input speed 4000 Gear ratio 24.34 Weight (excluding oil) Oil volume 8) 8) WHEEL WHEEL Item Specifications Type (front/rear) Solid (opt: No-marking, air pressure) Quantity (front/rear) Front-wheel drive 8.15-15 (16PR) Rear-wheel drive...
  • Page 126: Fastening Torque

    3. FASTENING TORQUE 3. FASTENING TORQUE Screw Sequences Item kgf·m specifications hydraulic pump motor mounting nut M8 × 1.25 3.4 ± 0.7 Electric systems Drive motor mounting bolt M10 × 1.5 6.9 ± 1.4 hydraulic pump mounting bolt M10 × 1.5 6.9 ±...

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