1. Daily inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1

2. Do's and dont's - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-2

3. Seat belts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-4

4. No riders - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5

5. Pedestrians - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6

6. Operator protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-7

7. Fork safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-8

8. Pinch points - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9

9. Travel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-10

10. Grades, ramps, slopes and inclines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-11

11. Tip over - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-12

12. Surface and capacity - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-14

13. Parking - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-15

14. Refueling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-16

15. Step - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-17

16. Operator's safety rules - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-18

2. OPERATING HAZARDS

1. Loose loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1

2. Long and wide loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2

3. Rear swing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2

4. Low overhead clearance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3

5. Fast turns and high loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3

6. Right angle stacking - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4

7. Chain slack - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4

8. Pallets and skids - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5

9. Caution for electrical lines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5

10. Lifting loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6

11. Side shift - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6

12. Fork positioner - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-8

3. KNOW YOUR TRUCK

1. General locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1

2. Data/safety plate and decal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2

3. Cab devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-4

4. Cluster - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-5

CONTENTS

Table of Contents

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Summary of Contents for Hyundai 110D

Page 1: Table Of Contents
CONTENTS 1. SAFETY HINTS 1. Daily inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 2.
Page 2 5. Transmission message indicator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-16 6.
Page 3 7. Service instruction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19 8.
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 HYUNDAI reserves the right to make improvements and changes in specifications or design, without notice and without incurring obligation. Please check with your authorized HYUNDAI dealer for information on possible updates or revisions.
Page 7 Acquaint yourself with the various procedures in this manual. Understand how all gauges, indicator lights, and controls function. Please contact your authorized HYUNDAI dealer for the answers to any questions you may have about your lift truck's features, operation, or manuals.
Page 8 E E C REGULATION APPROVED · Noise level (2000/14/EC and EN 12053) are as followings. Model (EU only) 110D/130D/140D/160D-7E 108 dB 78 dB · The value of vibrations transmitted by the operator's seat are lower than standard value of (2002/44/EC)
Page 9: Safety Labels
SAFETY LABELS 1. LOCATION Always keep these labels clean. If they are lost or damaged, attach them again or replace them with a new label. RADIATOR TOP RCV LEVER SWITCH PANEL CABIN INSIDE-RH CABIN INSIDE-LH 28,29,30 160D7EOM101 Logo 11 Hook 21 Attach Fork 12 Hook...
Page 10 2. DESCRIPTION There are several specific warning labels on this machine please become familiarized with all warning labels. Replace any safety label that is damaged, or missing. FORK(ltem 2) This warning label is positioned on the left side of the mast. Never stand or work under the raised forks even if the hydraulic safety lock lever is applied.
Page 11 HAND CAUTION (Item 7) This warning label is positioned on the top side of mast. It warns 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 12: Safety Instructions
SAFETY INSTRUCTION (Item 13) Truck for USA or equipped with *OPSS. This warning label is positioned on the inside of cabin door if the truck is for USA or equipped with *OPSS. SAFETY INSTRUCTIONS This forklift is equipped with an operator This forklift is equipped with an operator existence sensing system per ANSI/ASME existence sensing system per ANSI/ASME...
Page 13 GUIDE 1. DIRECTION The directions of this truck indicate forward, Front backward, right and left when truck is in the travelling direction. Left Right Rear 160D7SM01 2. SERIAL NUMBER Inform following when you order parts or the truck is out of order. TRUCK SERIAL NUMBER It's shown on front of the right side frame.
Page 14: 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 15: Do's And Dont's
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. 160D7OM04 Don't smoke in NO SMOKING areas or when refueling. D35AOM06...
Page 16 Don't operate the truck outdoors in rainy day. ※ E xclude the truck equipped cabin. 160D7OM07 Exhaust gas is dangerous. Do not operate the truck at the inhouse, if possible. Provide adequate ventilation when working in a closed space. 160D7OM08...
Page 17: Seat Belts
3. SEAT BELTS Always buckle up for the truck equipped with safety belt. 160D7OM09 Seat belts can reduce injuries. 160D7OM11...
Page 18: No Riders
4. NO RIDERS The operator is the only one who should be on a truck. 160D7EOM12 Never transport personnel on the forks of a lift truck. 160D7EOM14...
Page 19: 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. 160D7EOM05 Watch for people in your work area even if your truck has warning lights or alarms.
Page 20: Operator Protection
6. OPERATOR PROTECTION Stay inside the cabin. Always keep your body within the confines of the truck. Do not operate truck without cabin or overhead guard, unless condition prevent use of it. 160D7EOM16...
Page 21: Fork Safety
7. FORK SAFETY Never allow anyone to walk under raised forks. D255OM17A There is special equipment to raise people for overhead work. DO NOT USE LIFT TRUCKS. 160D7EOM14 Always lower the load slowly. Raise and lower with mast vertical or tilted slightly back(Never forward).
Page 22: Pinch Points
8. PINCH POINTS Keep hands, feet and legs out of the mast. D255OM61 Don't use the mast as a ladder. 160D7EOM62 Never try to repair the mast, carriage, chain, or attachment by yourself. Always get a trained mechanic. 160D7EOM63...
Page 23: 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. 160D7EOM18 When handling bulky loads that restrict your vision operate your truck in reverse to improve visibility.
Page 24: Grades, Ramps, Slopes And Inclines
10. GRADES, RAMPS, SLOPES AND INCLINES Never turn on a grade, either loaded or unloaded. Unloaded-Forks downgrade 160D7EOM30 Loaded - Forks upgrade 160D7EOM33 1-11...
Page 25: 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 26 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 27: 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 SAND use.
Page 28: Parking
13. PARKING Never park on a grade. 160D7EOM41 Always come to a complete stop before leaving truck. Be sure travel control is in NEUTRAL. 160D7EOM42 Lower forks fully to floor and tilt forward. 160D7EOM44 Set parking brake. Position 1 : OFF(Release) Position 2 : ON(Lock) Turn key to OFF position.
Page 29: Refueling
14. REFUELING Before adding oil, check around truck for oil leakage. 160D7EOM47 Keep away from fire when adding oil or during operation. 160D7OM48 After adding oil, wipe off any oil spilled on truck. 160D7EOM49 1-16...
Page 30: Step
15. STEP When getting on or off the truck, use the step provided. 160D7EOM50 Do not jump up or down from the truck. 160D7EOM52 1-17...
Page 31: Operator's Safety Rules
16. OPERATOR'S SAFETY RULES All operational functions require that the operator be seated in the operator's seat. Always buckle up if a seat belt is provided. 160D7EOM18 Parking brake must be locked in the PARK POSITION before exiting from the vehicle. 1.
Page 32: Operating Hazards
2. OPERATING HAZARDS 1. LOOSE LOADS Loose or unbalanced loads are dangerous. Observe these precautions. Never carry loose or uneven material. 160D7EOM53 Center wide loads. 160D7EOM55 Stack and band loose material. D35AOM41 Avoid sudden braking or starting When the truck is loaded, do not drive at maximum speed.
Page 33: Long And Wide Loads
2. LONG AND WIDE LOADS With long or wide loads, you need more room. 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-swing when turning.
Page 34: Low Overhead Clearance
4. LOW OVERHEAD CLEARANCE Know the height of your truck, with and without a load. Check your clearances. Keep the load low and tilted back. 160D7OM73 Watch overhead clearance: Moving into overhead structures can tip a truck over, or spill a load. 160D7OM74 5.
Page 35: Right Angle Stacking
6. RIGHT ANGLE STACKING When right angle stacking or moving with a raised load to clear low objects, avoid sharp turns and move slowly. 160D7OM75 7. CHAIN SLACK Slack chains mean rail or carriage hang- Raise the forks before you move, or broken chains can result.
Page 36: Pallets And Skids
8. PALLETS AND SKIDS Do not move or store materials on damaged pallets or skids. Items can fall through them causing severe injury or death. Be sure the pallet or skid you are using is in good condition and does not have defective or missing components and fasteners.
Page 37: Lifting Loads
10. LIFTING LOADS Never permit any persons to stand or pass under lifted load. 160D7EOM58 Never use wire rope to lift a load. 160D7EOM60 11. SIDE SHIFT Never operate the side shift while the forks are not equipped with supports such as a load table for the load.
Page 38 It should be observed that the side shift with load is operated in netural position before traveling. When operating side shift with load, operate slowly so that it can not avoid from dropping of the load or overturning of the fork lift. 160D7EOM73 Never move the load to push or pull of it by the side shift.
Page 39: Fork Positioner
12. FORK POSITIONER Do not operate the fork positioner with a load, or with the fork arm on the ground. Never move the levers to operate the pork positioner suddenly and quickly. It can be caused to drop the load. 160D7EOM75...
Page 40: Know Your Truck
3. KNOW YOUR TRUCK 3. KNOW YOUR TRUCK 1. GENERAL LOCATIONS 1. GENERAL LOCATIONS 1) 1) 110D/130D/140D/160D-7E 110D/130D/140D/160D-7E 160D7EOM54 Mast Tilt cylinder 13 Bonnet Lift chain Cabin 14 Counterweight Lift cylinder Head light-fender 15 Rear wheel Fork positioner cylinder 10 Work lamp-mast...
Page 41: Data/Safety Plate And Decal
Truck serial number An identification number assigned to this particular truck and should be used when requesting information or ordering service parts for this truck from your authorized HYUNDAI dealer. The serial number is also stamped on the frame. (4) (4)
Page 42 OPERATOR SAFETY WARNING DECAL 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! AVOID : -slippery, sloping, or uneven surface -loads over capacity on nameplate...
Page 43: Cab Devices
3. CAB DEVICES The ergonomically designed console box and suspension type seat provide the operator with comfort. ELECTRONIC MONITOR SYSTEM The centralized electronic monitor system allows the status and conditions of the truck to be monitored at a glance. is equipped with a safety warning system for early detection of truck malfunction. Front Rear Radio and CD/MP3 palyer...
Page 44: Cluster
4. CLUSTER STRUCTURE The gauges panel consists of gauges and monitors as shown below, to warn the operator in case of abnormal truck operation or conditions for the appropriate operation and inspection. Gauges : Indicate operating status of the truck. Warning lamp : Indicate abnormality of the truck.
Page 45 Fuel gauge This gauge indicates the amount of fuel in the fuel tank. Fill the fuel when the indicator moves E point, refuel as soon as possible to avoid running out of fuel. If the gauge indicates below E point even though the truck is on the normal condition, check the electric device as that can be caused by the poor connection of electricity or sensor.
Page 46 Direction pilot lamp This lamp flashes when the signal indicator lever is moved. Work lamp pilot lamp (front / rear) This lamp lights ON when cabin work lamp switch is pressed. Head light pilot lamp This lamp comes ON when the main light switch is operated to 2nd step.
Page 47 This lamp lights ON and the T/M message display shows the error codes when an error occurs in the transmission. Immediately pull the truck to a convenient stop. Stop the engine. Investigate the cause. Consult a HYUNDAI dealer to investigate the cause. Do not operate until the cause has been corrected.
Page 48 (12) Air cleaner warning lamp This lamp operates by the vacuum caused inside when the filter of air cleaner is clogged. Check the filter and clean or replace it when the lamp is ON. (13) Battery charging warning lamp This lamp is ON after key switch is turned ON. Check the battery charging circuit when this lamp comes ON during engine operation.
Page 49 (17) Engine coolant temperature warning lamp This lamp is turned ON when the temperature of cooling water is over the normal temperature(104 C, 219 F). Check the cooling system when the lamp is ON. (18) Transmission oil temperature warning lamp This lamp informs the operator that transmission oil is above the specified temperature.
Page 50 CLUSTER BUTTON Each button has the following function. Buzzer stop button Next button MENU button Buzzer stop button This swich is used to stop the buzzer sound. Stop the buzzer when the switch is pressed. Menu and next button This swiches are used to choose the model or display the engine error on the LCD.
Page 51 LCD has the functions to display start mode, standby mode, cruise function, model select and engine error. Display Name Description Display initialization state with HYUNDAI logo and Start mode program version. Standby mode Displays on the idle state. Displays rpm, odometer and hourmeter Odometer is on, is activated.
Page 52 Display Name Description On model select mode, displays like this image. Model select Refer to the page 3-11. In case of below 4 engine errors displays like this Engine error display image. Refer to the page 3-11. In case of over 4 engine errors displays like this image.
Page 53: Transmission Message Indicator
5. TRANSMISSION MESSAGE INDICATOR 5. TRANSMISSION MESSAGE INDICATOR 1) 1) TRANSMISSION ERROR DISPLAY TRANSMISSION ERROR DISPLAY Function The display can be used with the gear selector. It indicates speed and driving direction as well as the activated inching. When driving in the automatic mode, a bar indicator gives additionally also information about the selected driving range ;...
Page 54 2) 2) DO AEB WORK DO AEB WORK Start engine after parking the machine on flat floor and blocking wheels. Release parking brake. With stepping on the service brake, operate T/M STALL(3 stage). (To avoid defect of clutch pack, repeat 10 sec of operation and 10 sec of placing neutral) When the T/M oil temperature reaches 75~80°C, lock the parking brake and then shift gear to neutral position to keep the machine at LOW RPM.
Page 55 3) 3) DISPLAY DURING AEB-MODE DISPLAY DURING AEB-MODE Symbol Meaning Remarks AEB-starter is plugged at the diagnostic plug AEB-Starter-button is pressed K1..K3 Calibrating clutch K1...K3, KV or KV, KR KR resp. _and Kx Wait for start, initialization of clutch Kx, x : 1, 2, 3, V, R ≡and Kx Fast fill time determination of clutch Kx =and Kx...
Page 56 INITIALIZING THE INCHING SENSOR INITIALIZING THE INCHING SENSOR Start engine after parking the machine on flat floor and blocking wheels. Release parking brake and keep neutral gear shift. Adjust the inching sensor linkage so that the regular voltage is supplied to inching sensor when operating the pedal.
Page 57: Switches
6. SWITCHES Cabin tilt switch DETAIL A STOP DOWN Cruise set-resume switch Cruise switch Main light switch Work lamp switch Hazard switch Cover(LH) Rear wiper/washer switch Aircon switch Seat heat switch Parking brake switch Cabin tilt switch Lock lever Auto/Manual select switch Inching switch DETAIL A Inc/Dec switch...
Page 58 HAZARD SWITCH Use for parking, or loading truck. If the switch is left ON for a long time, the battery may be discharged. INCHING SWITCH If this switch is pressed, inching operation is applied to inching pedal. Also, inching lamp on the cluster is illuminated. PARKING BRAKE SWITCH If this switch is pressed, the parking brake is applied and the gauge panel warning lamp will comes ON.
Page 59 REAR WIPER AND WASHER SWITCH This switch is used to operate the rear wiper and washer by two steps. First step : The rear wiper operates. Second step : The washer liquid is sprayed and the rear wiper is operated only while pressing. If release the switch, return to the f i r s t s t e p position.
Page 60: Horn Button
HORN BUTTON If you press the button on the top of the multifunction switch and the Horn button center of the steering wheel, the horn will sound. CAB LAMP SWITCH This switch turns ON the cab room lamp. MULTI FUNCTION SWITCH Front wiper and washer switch When the switch is in J position, the wiper moves intermittently.
Page 61: Power Mode
CRUISE SET/RESUME SWITCH Auto cruise function is used to travel at constant engine speed with RESUME a desired engine rpm. CRUISE This function is activated only when the CRUISE SWITCH is turned ON. If you want to travel the truck at constant speed, you raise the engine rpm and then press the CRUISE SET switch.
Page 62: Control Device
7. CONTROL DEVICE Lift lever Tilt lever Steering wheel 3-spool lever(opt) Gear selector lever 4-spool lever(opt) Inching pedal 5-spool lever(opt) Brake pedal Accelerator pedal LIFT LEVER LIFT PULL the lever BACK to LIFT the forks. Lower LOWER PUSH the lever FORWARD to LOWER the load. Lift HOLDING When the lever is released, the lifting or lowering action stops.
Page 63 LEVER FOR SIDE SHIFT LH MOVEMENT Push the lever forward to move the left hand for the side shift. RH MOVEMENT Pull the lever backward to move the right hand for the side shift. LEVER FOR SIDE SHIFT WIDTH FORK POSITIONER SIDE SHIFT (CLAMP TYPE) LH MOVEMENT Push the lever forward to move the left hand for the side shift.
Page 64 LEVER FOR SIDE SHIFT WIDTH FORK POSITIONER SIDE SHIFT LH MOVEMENT Push the lever forward to move the left hand for the side shift. RH MOVEMENT Pull the lever backward to move the right hand for the side shift. FORK POSITIONER LH FORK MOVEMENT Outward - Push the lever forward to move outward for the LH fork.
Page 65 GEAR SELECTOR LEVER This lever is used for gear selection, forward 3 stages and reverse 3 stages. If you push the gear selector lever, the truck moves forward, but pulling the gear selector lever, the truck moves backward. If you turn the gear selector lever forward, the truck increases the speed, but if you turn the gear selector lever backward, the truck reduces the speed.
Page 66 STEERING WHEEL LEVER By pulling down the lever, the wheel is adjustable to tilt. By pulling up the lever, the wheel is adjustable to telescope. 3-27...
Page 67: Air Conditioner And Heater
8. AIR CONDITIONER AND HEATER Air conditioner and heater are equipped for pleasant operation against outside temperature and defrost on window glass. Fan speed control switch Inlet change over switch Air position control switch Temperature control switch Air conditioner switch 3-28...
Page 68: Fan Speed Control Switch
FAN SPEED CONTROL SWITCH It is possible to control the fan speed to four steps. AIR POSITION CONTROL SWITCH This switch regulates the air position. Front Front & rear Rear Front & defrost Defrost TEMPERATURE CONTROL SWITCH This switch regulates the temperature of air. BLUE Right side(red zone) : Heat up air temperature Left side(blue zone) : Cool down air temperature...
Page 69: Others
9. OTHERS Front Engine control unit(ECU) Radio and CD/MP3 player Rear Transmission control unit(TCU) Monitor(opt) Handsfree(opt) Cigar lighter Fuse box Seat Seat 3-30...
Page 70: Cigar Lighter
SEAT The seat is adjustable to fit the contours of the operator's body. It will reduce operator fatigue due to long work hours and enhance work efficiency. Forward/Backward adjustment Pull lever A to adjust seat forward or backw-ard. The seat can be moved forward and backw-ard over 200mm(8in) in 10 steps.
Page 71 FUSE BOX The fuses protect the electrical parts and wiring START KEY from burning out. FUSE HOLDER The fuse box cover indicates the capacity of each TCU(B+) fuse and circuit it protects. TURN LAMP HORN(B+) Replace a fuse with another of the same capacity.
Page 72: Front Panel Presentation
RADIO AND MP3 PLAYER CD inserter FRONT PANEL PRESENTATION --- ----------- Power and volume switch ------------ Preset memory button 1 REW ----------- Fast rewind (CD) PWR ----------- Press to power on/off VOL ------------ Turn right/left to adjust the volume ------------ Preset memory button 2 ----------- Fast forward (CD) ------------AM/FM button (radio) ------------ Preset memory button 3...
Page 73 RADIO Power and volume switch Power ON/OFF This switch is used to turn the audio ON or OFF. Volume This switch turned to right or left, the sound is increased or FM/AM button You can broadcasting on AM or FM band by pressing this band selection button.
Page 74 Preset memory button Manually storing stations in a preset Six stations per band can be stored and recalled using the preset keys (1 to 6). Tune in to the desired station. Press the desired preset key (1 to 6) for more than 0.8 seconds to store the current tuned station.
Page 75 CD/MP3 PLAYER CD playback button It is possible to change CD playback during broadcasting. If there was no CD on audio, "NO DISC" displays on LCD during 5 seconds. Track button CD player Short press : Select the next/previous track Long press : Select the fast forward or rewind MP3 player Memory file search up/down...
Page 76 Repeat track button(CD) Press this button to activate repeat current track playback. The LCD displays "RPT". It is canceled press one more this button. Mark button(MP3) Memory Press over 0.8 second, the current file memorized with a beep (max 100 tune memory). The LCD displays "M"...
Page 77 6) 6) RADIO AND USB PLAYER RADIO AND USB PLAYER (110D-7E : #0050-#0496, 130D-7E : #0019-#0278, 140D-7E : #0009-, 160D-7E : #0272-#1649) (110D-7E : #0050-#0496, 130D-7E : #0019-#0278, 140D-7E : #0009-, 160D-7E : #0272-#1649) ■BASIC FUNCTIONS BASIC FUNCTIONS 2209S3CD70 1 Power (PWR) button...
Page 78 ·Sound setting Sound setting ① Press the SELECT button to conduct sound setting. SELECT PUSH Each press of the button will change the sound setting in the following order. BASS → MIDDLE → TREBLE → BALANCE → EQ → BEEP 2209S3CD70C ②...
Page 79 (3) (3) MODE selection button MODE selection button ① Pres the MODE button to change to RADIO/USB/AUX/iPod modes. MODE However, the mode can be selected only when the respective media is connected. ② If iPod is connected to the audio, the mode will change in the following order.
Page 80 ■RADIO RADIO 2209S3CD71 1 Radio (FM/AM) selection button 4 LCD display 2 TRACK/SEEK button 5 BSM (Best Station Memory) button 3 Broadcast manual search (FLDR) button 6 Saving broadcast frequencies to PRESET numbers (1) (1) Radio Radio (FM/AM) selection button (FM/AM) selection button ①...
Page 81 (2) (2) TRACK/SEEK button TRACK/SEEK button ① As buttons used to automatically search broadcasts, pressing the button will automatically search and stop at a frequency with TRACK superior reception. TRACK ∧ : Searches frequencies higher than current frequency SEEK SEEK ∨: Searches frequencies lower than current frequency 2209S3CD71B ※...
Page 82 (6) (6) Saving broadcast frequencies to PRESET numbers Saving broadcast frequencies to PRESET numbers Up to 18 FM broadcasts and 6 AM broadcasts can be saved. ① Use the auto/manual search buttons to find the desired frequency. ② Select the preset button (1REW~ 6INFO) to which you wish to save the selected frequency.
Page 83 ■USB USB CONNECTION CONNECTION 2209S3CD72 1 USB selection button 7 Scroll (SCR) button 2 TRACK UP/SEEK DOWN button 8 View music info (INFO) button 3 FLDR UP/DOWN button 9 Scan button (BSM) 4 FF/REW button 10 Finding and playing file (SELECT) button 5 RPT/FOLDER RPT button 11 LCD display 6 RDM/FOLDER RDM button...
Page 84 (3) (3) FLDR UP/DOWN button FLDR UP/DOWN button ① If there are more than 2 folders in the USB, pressing the FLDR UP/ DOWN button will move to the previous or next folder. FLDR ② If there are no folders in the USB, then pressing the button will move FLDR up/down within the folder in 10 file increments.
Page 85 (8) (8) View music info iew music info (INFO) (INFO) button button ① Each time the INFO button is pressed, the info on the currently playing song will be displayed in the following order. FILE NAME → TITLE → ARTIST → ALBUM → DIR 2209S3CD72E (9) (9) Scan button...
Page 86 ■iPOD CONNECTION POD CONNECTION 2209S3CD73 1 iPod selection button 5 Random play (RDM) button 2 TRACK UP/SEEK DOWN button 6 Scroll (SCR) button 3 FF/REW button 7 View music info (INFO) button 4 Repeat (RPT) button 8 Finding and playing file (SELECT) button ·...
Page 87 (3) (3) FF/REW FF/REW button button ① While an iPod is operating, press and hold the FF button to fast- forward the song. ② When fast-forward is complete, the next song will properly play from the beginning even if you continue holding the button. Press and hold the REW button to rewind the song.
Page 88 (8) (8) Finding and playing file (SELECT) button Finding and playing file (SELECT) button ① While iPod is playing, press and hold the SELECT button for over 3 SELECT PUSH seconds to enter CATEGORY mode and search for desired files. ②...
Page 89 ■AUX connection AUX connection 2209S3CD74 · Operates only when an external device is connected to AUX. Connecting an AUX device to the audio using the AUX cable will automatically convert to AUX mode. · When an external device is connected, only the PWR, FM/AM, MODE, and VOL buttons can be operated.
Page 90 6) 6) RADIO AND USB PLAYER (WITH BLUETOOTH) RADIO AND USB PLAYER (WITH BLUETOOTH) (MACHINE SERIAL NO. 110D-7E : #0497-, 130D-7E : #0279-, 160D-7E : #1650-) (MACHINE SERIAL NO. 110D-7E : #0497-, 130D-7E : #0279-, 160D-7E : #1650-) 9403CD100 ■FRONT PANEL PRESENTATION...
Page 91 RADIO AND USB PLAYER (WITHOUT BLUETOOTH) RADIO AND USB PLAYER (WITHOUT BLUETOOTH) (MACHINE SERIAL NO. 110D-7E : #0497-, 130D-7E : #0279-, 160D-7E : #1650-) (MACHINE SERIAL NO. 110D-7E : #0497-, 130D-7E : #0279-, 160D-7E : #1650-) 9403CD101 ■FRONT PANEL PRESENTATION...
Page 92: Volume Up/Down
■GENERAL GENERAL (1) (1) Power and volume button Power and volume button ① Power ON / OFF Power ON / OFF button button Press power button (1) to turn the unit on or off. ② Volume Volume UP/DOWN UP/DOWN control knob control knob Turn VOL knob (1) right to increase the volume level.
Page 93 (2) (2) Menu Selection Menu Selection ① This button can adjust the effect of the sound and other things. Each time you press this button (2), LCD displays as follows : TREB BAL L=R FAD F=R LOUD ON BEEP 2ND On each setting, the level can be controlled by turning TUNE knob (2).
Page 94 ⑦ Loud control Loud control When listening to music at low volume levels, this feature will boost the bass and treble response. This action will compensate for the reduction in bass and treble performance experienced at low volume. To select the loudness feature, press button (2) until LOUD is displayed, then turn knob (2) right or left to activate or deactivate loudness.
Page 95 ■RADIO RADIO (1) (1) Mode button Mode button ① Repeat press MODE button to select FM1, FM2 or AM. 9403CD104 (2) (2) Manual tuning button Manual tuning button ① To manually tune to a radio station, simply turn encoder TUNE (2) left or right to increase or decrease the radio frequency.
Page 96 (5) (5) Preset scan (PS) / Best station memory (BSM) button Preset scan (PS) / Best station memory (BSM) button ① Press BSM button (12) momentarily to scan the 6 preset stations stored in the selected band. When you hear your desired station, press it again to listen to it.
Page 97 ■USB PLAYER USB PLAYER (1) (1) USB playback USB playback ① The unit was equipped with a front USB jack and also a rear USB Jack. With a USB device plugged in the front USB jack, it will be detected as front USB mode.
Page 98 (5) (5) Track Scan Play (SCAN) button Track Scan Play (SCAN) button SCAN playback : Simply press SCAN (12) button to play the first 10 seconds of each track. SCAN folder : Press and hold SCAN button for longer than 2 seconds to scan play the tracks in current folder.
Page 99 ■AUX OPERATION AUX OPERATION It is possible to connect your portable media player to the audio system for playback of the audio tracks via the cab speakers. To get the best results when connecting the portable media to the audio system, follow these steps : Use a 3.5 mm stereo plug cable to connect the media player headphone socket at each end as follows.
Page 100 ■BLUETOOTH BLUETOOTH (if equipped) (1) (1) Using a bluetooth wireless connection Using a bluetooth wireless connection ① Your audio unit supports bluetooth wireless technology. You can set up a wireless link with bluetooth cellular phone. ② Continue to pair the cellular phone with the audio unit. Within a few moments the two should be able to connect.
Page 101 ※ Please retry the pairing instruction if HYUNDAI does not appear on the cellular phone screen. Please retry the pairing instruction if HYUNDAI does not appear on the cellular phone screen.
Page 102 (4) (4) Bluetooth connection and disconnection Bluetooth connection and disconnection ① When established bluetooth connection is made between this audio unit and the cellular phone, bluetooth icon on the display appears and then the display shows HF/AV CONN when handsfree & AV profile is connected.
Page 103 (6) (6) Audio transfer between the audio unit and phone Audio transfer between the audio unit and phone The audio transfer function is for switching the call from the audio unit to the cellular phone for private conversation. ① Press CALL button (4) briefly during conversation, it appears CALL TRANS on the display.
Page 104 (9) (9) Using the audio unit as bluetooth music Using the audio unit as bluetooth music The audio unit supports A2DP (Audio Advanced Distribution Profile) and AVRCP (Audio Video Remote Control Profile), and both profiles are available to listen music at the audio unit via cellular phone which is supporting the two profiles above.
Page 105 ■RESET AND PRECAUTIONS RESET AND PRECAUTIONS (1) (1) Reset function Reset function Interfering noise or abnormal compressed files in the MP3 disc or USB instrument may cause intermittent operation (or unit frozen/locking up). It is strongly recommended to use appropriate USB storage to not cause any malfunction to the audio unit.
Page 106 7) 7) HANDSFREE HANDSFREE Allow you to dial a call or to have a conversation without holding your handset. Use the remote controller when making and answering a calls or ring off. Indicator lamp Private call jack socket Handsfree jack socket USB socket Mobile phone stroage box Service socket...
Page 107 (4) (4) Handsfree jack socket Handsfree jack socket ① Connect the jack cable when call by handsfree. ② Use the special adapter when jack cable is not interchangeable. ③ Check the jack type of mobile phone before use. 21093CD51D (5) (5) Indicator lamp Indicator lamp ①...
Page 108 (connection process of the mobile phone and handsfree), you can Call button hear beep sounds three times. 55I3CD26 ② The mobile phone finds bluetooth named " HYUNDAI". Select "HYUNDAI" and set "connect with Bluetooth on the mobile phone". HYUNDAI · Default password : 0000 PAIRING 55I3CD27 ③...
Page 109 8) 8) REMOTE CONTROLLER REMOTE CONTROLLER Radio handsfree jack External speaker LED (null) External speaker microphone (null) Handsfree jack MIC Power/volume switch External speaker switch (null) Handsfree mode button CALL button SEEK button SEEK button MODE button MUTE button TALK button Radio calling mode button 55I3CD31 (1) (1)
Page 110 (4) (4) Handsfree MIC Handsfree MIC ① This MIC transfers user voice to receiver of the call when making a call by handsfree. 55I3CD31D (5) (5) Seek button Seek button ① If this button pressed, the radio automatically stops at the next fre- quency of broadcasting for your listening.
Page 111 (8) (8) Radio calling mode button Radio calling mode button ① Press this button, activated or deactivated the radio handsfree func- tion. ② As long as you do not press this button, you can hear the other party. 55I3CD31H ③ The LED is turned ON when this button is activated.
Page 112: Monitor(Option)
MONITOR(OPTION) Adjusting the angle Upwards and downwards up to 7 total 14 . Swivels left and right up to 15 total 30 . Power button Enter button Left selection button Right selection button Camera / ESC button Power button To turn the power off or on. To switch the monitor on or off, press and hold the power button for two second.
Page 113 Name Description ESL(Engine Starting Limit) screen The password must be 5~10 digits long. After input password, you must input Default password : '0000000000'(digit '0', 10 times) Menu selection screen Camera selection To enter camera screen, press button. To return to menu selection screen, press button.
Page 114 Name Description Changing password The password must be 5~10 digits long. After input password, you must input Display set up screen LCD brightness To adjust to display brightness, press to decrease or increase. Language selection 3-57...
Page 115: 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 report the condition to the proper authority.
Page 116: Functional Checks
FUNCTIONAL CHECKS Check the operation of the truck as follows. ※ 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 Section 1 of this manual. Test warning devices, horn, light, and other safety equipment and accessories.
Page 117: Suggestion For New Truck
2. SUGGESTION FOR NEW TRUCK It takes about 100 operation hours to enhance its designed performance. Operate according to below three steps and avoid excessive operation for the initial 100 hours. Avoid excessive operation for Service meter Load initial 100 hours Until 10 hours About 60% Until 100 hours...
Page 118: Fuel Safety Practices
3. FUEL SAFETY PRACTICES REFUELING DIESEL TRUCKS 100D7OM106 Stop the engine when refueling. All lights and flames shall be kept at a safe distance while refueling. D35AOM106 DANGER DIESEL FLAMMABLE USE CLEAN, PROPERLY MARKED FUEL CANS D35AOM106 CLEAN UP SPILLS D35AOM106...
Page 119: 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 120: Check Before Operation
2 2 . CHECK BEFORE OPERATION The Occupational Safety and Health Act(OSHA) required that truck users examine their trucks before each shifts to be sure they are in safe working order. Defects when found shall be immediately reported and corrected. The truck shall be taken out of service until it has been restored to safe operating condition.
Page 121: Check Before Starting Engine
3. CHECK BEFORE STARTING ENGINE CHECK FOR WATER OR OIL LEAKAGE Walk around your HYUNDAI truck and check for water, oil or hydraulic leakage. Examine truck for obvious damage. Check cabin, backrest and forks for crack or obvious damage. If any damage or leaks are detected contact your HYUNDAI dealer or tire repair shop.
Page 122: Check Coolant Level
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. Normal 160D7OM61 In antifreeze is being used, pay careful attention to the ratio of antifreeze and water when adding coolant.
Page 123: Check Battery
CHECK FAN BELT TENSION Cooling fan belt tensioner Maintenance check With the engine turned off, check that neither the top nor bottom tensioner arm stop is touching the cast boss on the tensioner body. If either of the stops is touching a boss, the 7807AMI50 alternator belt must be replaced.
Page 124: Check Hydraulic Oil Level
In accordance with the mast equipped, the oil level differs. Lower limit ℓ(U.S.gal) Gauge V - mast TF - mast Model Level gauge 110D-7E Lower limit 111(29) TF440 ~ TF700 V300 ~ V700 160D7MA14 130D-7E Upper limit 123(32) TF440 ~ TF700...
Page 125 CHECK PEDALS Check for any catching or abnormal heaviness when depressing the pedals. Inching pedal ① Free play : Max 1° ② Interlock stroke with brake pedal : 7° Brake pedal ① Free play : Max 1°...
Page 126: Seat Adjustment
4. SEAT ADJUSTMENT 1 1 ) SEAT ADJUSTMENT The seat is adjustable to fit the contours of the operator's body. It will reduce operator fatigue due to long work hours and enhance work efficiency. Forward/Backward adjustment ① Pull lever A to adjust seat forward or backw- ard.
Page 127: 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. · Seat belt is buckled up. · Parking switch ON The parking brake is applied. ·...
Page 128: 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 129: Starting And Stopping The Engine
7 7 . STARTING AND STOPPING THE ENGINE CHECK INDICATOR LIGHTS Check if parking brake switch is ON. Gear selector lever Check if gear selector lever is in neutral position. Parking brake switch Turn the key to the ON position, and check following.
Page 130 STARTING ENGINE IN A COLD WEATHER ※ Sound horn to warn surroundings after checking if there are obstacles in the area. ※ Replace the engine oil and fuel referring to recommended oils at page 7-66. Fill the anti-freeze solution to the coolant as required.
Page 131 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. Do not operate the truck below this level.
Page 132: To Stop The Engine
(10) Check steering wheel. Check that steering wheel does not wobble or suddenly pull to one side. Check also for any abnormal heaviness in steering. (11) Check rear view mirror. Adjust the rearview mirror for best rearward visibility. TRANSMISSION COLD STARTING At an oil temperature in the shifting circuit <...
Page 133: Warming-Up Operation
8. WARMING-UP OPERATION ※ The most suitable temperature for the hydraulic 。 oil is about 50。 C (112。 F ). It can cause serious trouble in the hydraulic system by sudden operation when the Gear selector lever 。 hydraulic oil temperature is below 25。 C (77。...
Page 134: 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 135 SELECTING DIRECTION OF TRAVEL Push the direction control lever forward, center it , or pull it back Forward for FORWARD, NEUTRAL, or REVERSE, respectively. Traction is disabled in NEUTRAL. Reverse 160D7OM95 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 136: Traveling Of The Truck
10. TRAVELING OF THE TRUCK BASIC OPERATION Tilt back fully Traveling posture Lift the forks so that the forks are placed 15- 20cm(6~8in) above the ground and tilt back the mast fully. 160D7EOP10 Traveling operation When warm-up operation is completed after the engine is started, move the truck according to Gear selector lever the following procedure.
Page 137 ※ When traveling at high speed, do not abruptly decelerate by using the trans- mission lever, to slow down instead press the brake pedal. ※ When changing direction, check beforehand there is no obstacle in the direction you will be headed. ※...
Page 138 Stopping the truck ① Press the brake pedal to stop the truck. ② Put the gear selector lever in the neutral Gear selector lever position. Parking brake switch ③ Press the parking brake switch. 160D7EOP14 ④ Lower the forks to the ground. Low idling for 5 minutes 160D7EOP07...
Page 139 Stopping engine ※ If the engine is abruptly stopped before it has Gear selector lever cooled down, its service life may be Parking brake switch shortened. Avoid sudden stop except an emergency. ※ When the engine is overheated, do not stop immediately.
Page 140: Operating Safely
11. OPERATING SAFELY Safe operation is the responsibility of the operator. WATCH WHERE YOU ARE GOING. DON’T GO IF YOU CAN’T SEE... Before driving, check all around to be sure that your intended path of travel is clear of obstructions and pedestrians.
Page 141 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 142: Load Handling
12. 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 143 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 144 TRAVELING WITH LOAD Travel with load or carriage as low as possible and tilted back. Never travel with the load or carriage raised(elevated) in a high position. Do not elevate the load except during stacking. Observe all traffic regulations and watch for other traffic, pedestrians, and safe clearances. Always look in the direction of travel.
Page 145 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 146 STACKING To put a load on a stack ① Aproach slowly and align the lift truck and load squarely with the stack. D35AOM137 ② Raise the load as the lift truck nears the stack. D35AOM138 ③ 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 147 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 148: Shut Down Procedure
1 1 3. 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 or a slope. Never park in areas that block emergency routes or equipment, access to fire aisles, or stairways and fire equipment.
Page 149: Storage
14. 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 150: Transport
15. TRANSPORT PRECAUTIONS FOR LOADING AND UNLOADING Contact your HYUNDAI forklift distributor for advice regarding transportation of the truck. When loading or unloading the truck on or from a transporter, using loading ramp, the following precautions must always be observed.
Page 151: Loading And Unloading By Crane
16. LOADING AND UNLOADING BY CRANE Check the specification of the truck when you are going to hoist the truck. Use long wire rope and stay to keep the distance Stay Wire rope with the machine as it should avoid touching with the truck body.
Page 152: 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 153 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. Turn on the parking brake switch. Remove the key and, when necessary, block the wheels to prevent the truck from rolling.
Page 154: 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 24V negative-ground electrical system. The "Booster" battery must be fully charged and in good condition.
Page 155 Connect the jumper cables in the following sequence: To ground To starter switch ⓐ Connect a jumper cable from the Charged battery positive(+; red) terminal on one battery to the positive(+; red) terminal on the other battery. Never connect positive(+; red) to negative(-;...
Page 156: Introduction
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 157: 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 158 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, CAB and frame members must be carefully and regularly inspected and maintained in a safe operating condition.
Page 159 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 160: Instructions Before Maintenance
3. INSTRUCTIONS BEFORE MAINTENANCE INTERVAL OF MAINTENANCE You may inspect and service the machine by the period as described at based on service meter of LCD. Shorten the interval of inspect and service depending on site condition.(Such as dusty area, quarry, sea shore and etc.) Practice the entire related details at the same time when the service interval is doubled.
Page 161: Proper Maintenance
Engine and hydraulic components have been preset in the factory. Do not allow unauthorized personnel to reset them. Ask to your local dealer or Hyundai for maintenance advise it unknown. Drain the used oil and coolant in a container and handle according to the method of handling for industrial waste to meet with regulations of each province or country.
Page 162 PERIODICAL REPLACEMENT OF SAFETY PARTS These are the parts which the operator cannot judge the remained lifetime of them by visual inspection. Repair or replace if an abnormality of these parts is found even before the recommended replacement interval. Replacement of consumable service parts is not covered under warranty. Periodical replacement of safety parts Interval Every 2 to 4 years...
Page 163: Planned Maintenance Intervals
4. PLANNED MAINTENANCE INTERVALS MAJOR COMPONENTS LOCATION 160D7EOM21 Mast Transmission 17 Counterweight Lift cylinder 10 Torque converter 18 Radiator Steering unit 11 Engine 19 Seat Tilt cylinder 12 Steering cylinder 20 Cabin Main control valve 13 Hydraulic pump 21 Steering wheel Fork 14 Steering axle 22 Muffler...
Page 164 MAINTENANCE CHECK LIST EVERY 10 HOURS SERVICE Check items Service Remarks Visual inspection ·Truck for obvious damage and leaks. Check, Repair or Replace 7-14 ·Warning plates and decals. Check, Replace 7-14 ·Condition of tires and wheels. Air pressure. Check, Refill or Replace 7-16 ·Lift chain and fastener.
Page 165: Every 250 Hours Service
INITIAL 50 HOURS SERVICE Check items Service Remarks Engine oil Change 7-19 Engine oil filter Replace 7-19 INITIAL 100 HOURS SERVICE Check items Service Remarks Differential gear oil Change 7-41 Transmission oil and filter Replace 7-38 Brake cooling oil Change 7-42 EVERY 250 HOURS SERVICE Check items...
Page 166 Hydraulic oil(* Replace 7-33 Conventional hydraulic oil EVERY 5000 HOURS SERVICE Check items Service Remarks Replace 7-33 Hydraulic oil(* Hyundai genuine long life hydraulic oil (10) HEN REQUIRED Check items Service Remarks Fuel system 7-27 ·Fuel tank Drain or Clean 7-29 ·Water separator...
Page 167: Maintenance Locations
5 5 . MAINTENANCE CHART MAINTENANCE LOCATIONS 160D7EMA011 CAUTION Service intervals are based on the hourmeter reading. Stop the engine when servicing. Do not open the cap or drain plug to avoid injury by unexpected spouting of high temperature fluid or gas.
Page 168: Maintenance Chart
Change Hydraulic oil 5000 Hours Change Hydraulic oil *1 Conventional hydraulic oil 2 Hyundai genuine long life hydraulic oil Oil symbol Refer to the recommended lubricants for specification. DF : Diesel fuel HO : Hydraulic oil EO : Engine oil...
Page 169: 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 170 Fork length Height Model (mm) difference(mm) below 1500 Height difference 110D/130D/140D/160D-7E above 1500 D35AOM150 If the fork blade at the heel is worn down by more than 10%, the load capacity is reduced and the fork must be replaced. Shank Inspect the forks for twists and bends.
Page 171: Wheel And Tires
WHEEL AND TIRES Check the condition of the drive and steering wheels and tires. Remove objects that are embedded in the tread. Inspect the tires for excessive wear and breaks or chunking out. Check all wheel lug nuts or bolts to be sure none are loose or missing.
Page 172 TILTING CABIN Keep clearance of people except the operator before tilting the cabin. Before tilting the cabin, make sure that the mast is vertical or tilted forward. Otherwise, the operation could be blocked by mast tilt cylinders. Locate the truck on the plain and stable floor. Apply parking brake before servicing.
Page 173 Do not operate the tilt control switch or any control parts while servicing under the tilted cabin. It can cause severe injury or death. WARN OPERATE 160D7EMI64 The angle of fully tilted cabin is 65 。。 and the safety lock function operates within the tilting angle of 20 。...
Page 174: Service Instruction
7. SERVICE INSTRUCTION CHECK ENGINE OIL LEVEL Check the oil level with the machine on a flat Engine oil fill ground before starting engine. Pull out the dipstick and wipe with a clean cloth. Check the oil level by inserting the dipstick completely into the hole and pulling out again.
Page 175 Apply a light film of lubricating oil to the gasket sealing surface before installing the filter. Fill the filter with clean lubricating oil before installation. 7803A6MI07 Install the filler to the filter head. Mechanical over-tightening may distort the threads or damage the filter element seal. 160D7MI03 Clean and inspect the oil drain plug threads and the seal surface.
Page 176 (10) Operate the engine at low idle and inspect for leaks at the filter and the drain plug. Shut the engine off and check oil level with dipstick. Allow 15 minutes for oil to drain down before checking. Do not overfill the engine with oil. 160D7MI05 CHECK COOLANT LEVEL Check the coolant level at reservoir tank.
Page 177 FLUSHING AND REFILLING OF RADIATOR Change coolant Avoid prolonged and repeated skin contact with used antifreeze. Such prolonged repeated contact can cause skin disorders or other bodily injury. Avoid excessive contact-wash thoroughly after contact. Keep out of reach of children. 160D7EMI31 Protect the environment : Handling and disposal of used antifreeze can be subject to...
Page 178 The system must be filled properly to prevent air locks. During filling, air must be vented from the engine coolant passages. Wait 2 to 3 minutes to allow air to be vented; then add mixture to bring the level to the top. Adequate venting is provided for a fill rate of 19 liters/minute (5 U.S.gal/minute).
Page 179 Cooling system filling The system must be filled properly to prevent air locks. During filling, air must be vented from the engine coolant passages. Wait 2 to 3 minutes to allow air to be vented; then add mixture to bring the level to the top. The system has a design fill rate of 19 liters per minute (5 U.S.gallons per minute).
Page 180: Drive Belt
CLEAN RADIATOR AND OIL COOLER NOT OK Check, and if necessary, clean and dry outside of radiator and oil cooler. After working in a dusty place, clean radiator more frequently. Visually inspect the radiator for clogged radiator fins. 550kPa (80psi) Use 550kPa(80psi) air pressure to blow the dirt and debris from the fins.
Page 181 BELT TENSIONER, AUTOMATIC ADJUSTMENT Every 1000hours, or 1 year, whichever occurs first, inspect the automatic belt tensioner. With the engine turned off, check that neither the top nor bottom tensioner arm stop is touching the cast boss on the tensioner body. If either of the stops is touching a boss, the alternator belt must be replaced.
Page 182: Cleaning Of Air Cleaner
A worn tensioner that has play in it or a belt that “walks” off its pulley possibly indicates pulley misalignment. Maximum pulley mislignment is three degrees. This measurement can be taken with a straightedge and an inclinometer. Install the belt. 7807AMI54 CLEANING OF AIR CLEANER Wing nut...
Page 183: Replacement Of Fuel Filter
FUEL TANK Strainer & cap Fill fuel fully when system the operation to minimize water condensation, and check it with fuel gauge before starting the machine. Fuel tank Drain the water and sediment in the fuel tank by opening the plug. Be sure to LOCK the cap of fuel tank.
Page 184 REFILTER Inspect or drain the collection bowl of water daily and replace the element every 500hours. Drain water Bowl Open bowl drain valve to evacuate water. Drain valve Open Close drain valve. Close 2907A6MI20 eplace element Drain the unit of fuel. Follow "Drain water" instructions above.
Page 185: Bleeding The Fuel System
BLEEDING THE FUEL SYSTEM Air in fuel Do not vent the fuel system on a hot engine; this can cause fuel to spill onto a hot exhaust manifold, which can cause a fire. The replacement of fuel supply lines, fuel filters, fuel injection pump, high-pressure fuel lines, and injectors will let air enter the fuel system.
Page 186 A source that is often overlooked for air to enter the fuel system is between the inlet of the prefilter and the suction tube in the tank. Fuel tanks that have the outlet fitting at the top have a suction tube that extends to the bottom of the tank.
Page 187: Hydraulic Oil Check
LEAKAGE OF FUEL Be careful and clean the fuel hose, injection FIRE !!! pump, fuel filter and other connections as the leakage from these part can cause fire. 75776MI16 HYDRAULIC OIL CHECK Level gauge Lower the forks on the ground at a flat location as in the illustration.
Page 188: Change The Hydraulic Oil
CHANGE THE HYDRAULIC OIL Air breather Lower the forks on the ground and extend the tilt cylinder to the maximum. Loosen the cap and relieve the pressure in the tank. Prepare a suitable drain pan. To drain the oil loosen the drain plug. After draining oil, tighten the drain plug.
Page 189 REPLACEMENT OF ELEMENT IN HYDRAULIC Air breather TANK BREATHER Loosen the cap and relieve the pressure in the tank. Loosen the screw and remove the cover. Pull out the filter. Replace the filter with new one. Air breather Screw Reassemble by reverse order of disassembly. Tightening torque : 0.2~0.3kgf m(1.4~2.1lbf ft) Filter 160D7EMI18...
Page 190: Tire Pressure
Recommended tire pressure(When tire is cooled) Pressure Model Size Normal 8.0kgf/cm (114psi) 110D/130D-7E 10.00-20, 16PR 8.7kgf/cm (124psi) 140D/160D-7E 12.00-20, 20PR Continuous operation will produce heat and increase pressure on tire. But such phenomenon was already taken into account when designing a tire.
Page 191: Replacement Of Tire
Do not use recycled wheel parts. When removing lockering or inflating tire, use safety cable or chain to ensure safety. Be sure to bleed air before removing lockering. Never inflate tires unless the lockering is assembled in its place. Avoid the followings when traveling. Rubbing tires against road bank or rack at cargo-unloading spot.
Page 192 Loosen slightly all wheel mounting. Tools : Socket 32mm Torque wrench Extension bar Lift the machine with a jack. Loosen all wheel mounting nuts and replace the tire. Torque wrench 160D7MI37 Direction of tire to be installed Be careful that the valve should be facing the outside.
Page 193: Check Transmission Oil Level
CHECK TRANSMISSION OIL LEVEL The oil level check must be carried out as follows; oil level check(weekly). At horizontally standing machine. Transmission in neutral position. In cold start phase, the engine must be running about 2~3minutes at idling speed, and the marking on the oil level gauge must then be lying above the cold start mark COLD.
Page 194 Remove the transmission oil filter cartridge. Dispose of the used transmission oil filter cartridge properly. Clean the filter cartridge mounting base. Remove any part of the filter cartridge gasket that remains on the filter cartridge mounting base. Transmission oil filter Apply a light coat of oil to the gasket of a new transmission oil filter cartridge.
Page 195 CLEANING TRANSMISSION AIR BREATHER Remove dust or debris around the air breather. Air breather Remove the air breather and wash it with cleaning oil. 160D7MI45 CHECK AND SUPPLYING AXLE OIL Move the machine to flat ground. Air breather Open the axle air breather to relieve internal air pressure.
Page 196 If the oil level is below the plug hole, supply oil Planetary gear through a plug hole. When checking the oil level, press the parking brake switch and fix front and rear Plug frames using the safety lock bar. HORIZ OIL FILL LEVEL As the machine is hot after operation, wait...
Page 197 Supply oil into the differential gear and the Differential gear planetary gear. Oil amount : 19 (5.0U.S. gal) (Differential gear)+2 1.7 (0.4U.S. gal) (Planetary gear) Supply oil until it overflows from the oil filler, then install the plug. s the machine is hot after operation, wait Fill &...
Page 198 LUBRICATION Supply grease through the grease nipple, using grease gun. After lubricating, clean off spilled grease. Press the parking brake switch and fix front and rear tires with blocks. Set the mast and forks in a stable position and turn the hydraulic safety lock valve into the lock position.
Page 199 MAINTENANCE OF WORK EQUIPMENT Lubricate to each point of working device. Lubricate the grease to grease nipple in accordance with lubrication intervals. Description Fork adjustment cylinder pin Fork shaft Tilt cylinder pin Load chain Mast support pin Chain sheave pin Shorten lubricating interval when working in the water or dusty place.
Page 200: Electrical System
8. ELECTRICAL SYSTEM WIRING, GAUGES Check regularly and repair loose or malfunctioning gauges when found. Loose Open 160D7MI56 Welding repair Before start to welding, follow the below procedure. Shout off the engine and remove the starting switch. Disconnect ground cable from battery by master switch.
Page 201: Air Conditioner And Heater
9. AIR CONDITIONER AND HEATER CLEANING AND REPLACING FILTER Recircular Always stop the engine before servicing. plenum assy Open the door, loosen the wing bolt and remove the recircular plenum assembly. 160D7EMI58 Clean the recircular plenum using a pressurized air(Below 2kgf/cm , 28psi).
Page 202: Replacement And Check
10. REPLACEMENT AND CHECK 10. REPLACEMENT AND CHECK 1) 1) WIRING, GAUGES WIRING, GAUGES Check regularly and repair loose or malfunctioning gauges when found. 13036MI29 2) 2) BATTERY BATTERY (1) (1) Clean Clean ① Wash the terminal with hot water if it is contaminated, and apply grease to the termi- nals after washing.
Page 203: Air Cleaner Element
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 Neg(-) 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 204 OSHA approved eye protection rated for 200kPa(30psi) is required for air cleaning operation. Replace element if exhaust is black, or if lack of engine power is noted even after cleaning or element. When cleaning the element or element housing, cover the air flow outlet port of the housing with a clean cloth or tape to prevent dirt or dust from entering.
Page 205: Transmission Oil
TRANSMISSION OIL Do not touch hot components or allow hot oil to contact your skin. Transmission oil Park the truck in a level place and lower the forks. Then stop the engine and apply the Dipstick parking brake. Oil level check Open inspection plate, and oil level can be checked using dipstick.
Page 206: Hydraulic Tank
HYDRAULIC TANK Hydraulic oil change Park the truck in a level place and lower the forks. Then stop the engine and apply the parking brake. Change oil after removing drain plug on tank bottom. Drain Plug Drain 160D7EOM28 Strainer Cleaning OSHA-approved eye protection rated for 200kPa(30psi) is required for air cleaning operation.
Page 207: Cooling System
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. Block the tire at the opposite corner from the tire to be replaced.
Page 208 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 209: Fuses Replacement
FUSES REPLACEMENT Fuse box #1 No. Capacity Color Related electrical component START KEY Start key FUSE TCU(B HOLDER TCU(B+) Turn lamp OPSS(B Blue ECU(B TURN LAMP HORN(B+) Blue ECU(B CD/MP3(B OPSS(B+) MONITOR(B+) Room lamp Cluster(B ECU(B+) CABIN TILT Blue Cabin tilt Monitor(B Horn(B ECU(B+)
Page 210 LAMP BULBS REPLACEMENT Lamp Spec(24V) Head lamp(up) Head lamp(down) Turn signal lamp Clearance lamp Stop lamp Backup lamp License lamp (option) 3.4W 160D7EOM69 Beacon lamp (option) Strobe type Rear work lamp After checking that the fuse is not blown and that there is no disconnection in the wiring harness, replace the lamp bulb.
Page 211 Service brakes and inching pedal With the direction control in NEUTRAL and the engine running, push the sevice brake pedal fully down and hold. The brakes should apply before the pedal reaches the floorplate. If the pedal continues to creep downward, report the failure immediately. Do not operate the truck until the brakes are repaired.
Page 212 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 213 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 214 OIL PERFORMANCE DESIGNATION: To help achieve proper engine performance and durability, use only engine lubricating oils of the proper quality. For diesel engines, HYUNDAI recommends that you use motor oil that meets API service classification API CH-4 or better (SAE 15W-40) for diesel engines.
Page 215: Air Cleaning
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 216 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 217 All chains must be replaced if any link has wear of 3% or more, or if any of the damaged conditions notes above are found during inspection. Order replacement chains from your HYUNDAI dealer. Replace all chains as a set. Do not remove factory lubrication or paint new chains. Replace anchor pins and worn or broken anchors when installing new chains.
Page 218: Handling Truck In Extremely Hot Places
11. HANDLING TRUCK IN EXTREMELY HOT PLACES Pay careful attention particularly to the following points when handling the truck 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 219: Cold Weather Operation
12. COLD WEATHER OPERATION PREPARATION FOR LOW TEMPERATURE Replace lubrication oil with oil of the prescribed Min ambient temperature viscosity. (。 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。...
Page 220: Recommendation Table For Lubricants
SAE 10W-30/15W-40(API CH4 class or better) T/M oil Engine oil SAE10W-30(API CF4 class or better) Axle oil/Brake cooling oil SAE 80W-90/Donax TD ISO VG46/VG68, Hyundai genuine long life hydraulic oil Hydraulic oil ★ 1 ISO VG15, Conventional hydraulic oil Grease Lithium base grease NLGI No.2...
Page 221: Fuel And Lubricants
If any engine oil of API service class CF is used instead of class CH4 engine oil, the frequency of oil change must be doubled. Cold region : Russia, CIS, Mongolia Ultra low sulfur diesel : sulfur content 15 ppm Machine serial No. 110D-7E : -#0365 130D-7E : -#0145 140D-7E : -#0031 160D-7E : -#1169 110D-7E : #0366-...
Page 222: Specification
8. SPECIFICATIONS 1. SPECIFICATION TABLE 110D/130D-7E C' C 160D7ESP011 Model Unit 110D-7E 130D-7E Capacity 11,000 13,000 Load center Weight(Unloaded) 15797 16503 Lifting height 3300 Free lift Lifting speed(Unload/Load) Fork mm/sec 510/440 510/430 Lowering speed(Unload/Load) mm/sec 460/510 L W T L,W,T...
Page 223 140D/160D-7E C' C Model Unit 140D-7E 160D-7E Capacity 14,000 16,000 Load center Weight(Unloaded) 18378 19235 Lifting height 3300 Free lift Fork Lifting speed(Unload/Load) 450/360 450/350 mm/sec Lowering speed(Unload/Load) 390/430 mm/sec L,W,T L W T 1350 200 85 1350 200 90 Tilt angle (forward/backward) 15/12 degree...
Page 224: Specification For Major Components
2. SPECIFICATION FOR MAJOR COMPONENTS 110D/130D-7E ENGINE Item Specification Unit Model CUMMINS QSB6.7 Type 4 cycle turbocharged diesel type Cooling Method Water cooling Number of cylinders and arrangement 6 cylinders, In-line Firing order 1-5-3-6-2-4 Combustion chamber type Direct injection mm(in) Cylinder bore X stroke 107 124mm(4.21"...
Page 225: Steering Unit
STEERING UNIT Item Unit Specification Load sensing/Non load reaction/Dynamic signal Type Capacity cc/rev 45.4 Rated flow POWER TRAIN DEVICES Item Specification Model F & S 300* OZG 040/18(ZF SACH) Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.3 : 1 Type Full auto, power shift...
Page 226 140D/160D-7E ENGINE Item Unit Specification Model CUMMINS QSB6.7 Type 4 cycle turbocharged diesel type Cooling Method Water cooling Number of cylinders and arrangement 6 cylinders, In-line Firing order 1-5-3-6-2-4 Combustion chamber type Direct injection mm(in) Cylinder bore X stroke 107 124mm(4.21" 4.88") cc(cu in) Piston displacement 6700(410)
Page 227 STEERING UNIT Item Unit Specification Load sensing/Non load reaction/Dynamic signal Type Capacity cc/rev 45.4 Rated flow POWER TRAIN DEVICES Item Specification Model F&S 300* OZG 040/18(ZF SACH) Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.3 : 1 Type Full auto, Power shift Gear shift(FR/RR)
Page 228: Tightening Torque
3. TIGHTENING TORQUE 110D/130D-7E Item Size kgf·m lbf·ft Engine mounting bolt, nut M24 × 3.0 100 ± 15 723 ± 109 Engine Radiator mounting bolt, nut M12 × 1.75 12.8 ± 3.0 93 ± 22 Hydraulic pump mounting bolt M12 × 1.75 9.0 ±...
Page 229 140D/160D-7E Item Size kgf·m lbf·ft Engine mounting bolt, nut M24 × 3.0 100 ± 15 723 ± 109 Engine Radiator mounting bolt, nut M12 × 1.75 12.8 ± 3.0 93 ± 22 Hydraulic pump mounting bolt M12 × 1.75 9.0 ± 0.5 65 ±...
Page 230: Troubleshooting
9 . TROUBLESHOOTING 1. ENGINE SYSTEM Trouble symptom robable cause Remedy Oil pressure caution lamp fails ·Low oil level in oil pan. ·Add oil. to go out. ·Oil filter element clogged. ·Replace element. ·Loose or worn oil pipe joint leaks oil. ·Check and repair.
Page 231: Electrical System
2. ELECTRICAL SYSTEM Trouble symptom robable cause Remedy Lamps dimming even at maxi- ·Faulty wiring. ·Check for loose terminal and discon- mum engine speed. nected wire. Lamps flicker during engine ·Improper belt tension. ·Adjust belt tension. operation. ·Charge lamp defective. ·Replace.
Page 232 3 3 . TORQUE FLOW SYSTEM Trouble symptom robable cause Remedy 1. Excessive oil temperature rise ·Improper oil level. ·Check oil level. Add or drain oil as 1) Torque converter necessary. ·Impeller interfering with surroundings. ·After draining oil from oil tank and tra- nsmission, check and replace interfe- ring parts.
Page 233 Trouble symptom robable cause Remedy 3.Low output power 1) Torque converter ·Insufficient hydraulic pressure : - Low oil level. - Check oil level and add oil - Air sucked in. - Check joints and pipes. If necessary, retighten joint or repla- ce packing.
Page 234 Trouble symptom robable cause Remedy 4.Unusual oil pressure 1) Oil pressure is high ·Control valve malfunctioning. (1)Check for spool operation. If necessary, replace valve. (2)Check for clogging of small hole in valve body. If necessary, clean or repair. ·Cold weather. (high oil viscosity) ·When atmospheric temp is below fr- eezing point (when normal oil pressure is recover-...
Page 235 Trouble symptom robable cause Remedy 5. Power is not transmitted ·Foreign matter intruding into oil pass- ·Disassemble, check and repair or (Continue) age to clutch. replace. ·Shaft spline worn. ·Disassemble, check and replace. 6. Oil leakage ·Oil leaks from oil seal. ·Disassemble and check for wear of (Transmission and torque seal lips and mating sliding surfaces...
Page 236: Steering System
4. STEERING SYSTEM Trouble symptom robable cause Remedy 1. Steering wheel drags. ·Low oil pressure. ·Check locknut. Repair. ·Bearing faulty. ·Clean or replace. ·Spring spool faulty. ·Clean or replace. ·Reaction plunger faulty. ·Replace. ·Ball-and-screw assembly faulty. ·Clean or replace. ·Sector shaft adjusting screw excessi- ·Adjust.
Page 237: Brake System
5. BRAKE SYSTEM Trouble symptom robable cause Remedy 1. Insufficient braking force ·Hydraulic system leaks oil. ·Repair and add oil. ·Hydraulic system leaks air. ·Bleed air. ·Disk worn. ·Replace ·Brake valve malfunctioning ·Repair or replace. ·Hydraulic system clogged ·Clean. 2. Brake acting unevenly. ·Tires unequally inflated.
Page 238: Hydraulic System
6. HYDRAULIC SYSTEM Trouble symptom robable cause Remedy 1. Large fork lowering speed. ·Seal inside control valve defective. ·Replace spool or valve body. ·Oil leaks from joint or hose. ·Replace. ·Seal inside cylinder defective. ·Replace packing. 2. Large spontaneous tilt of ·Tilting backward : Check valve defec- ·Clean or replace.
Page 239: Testing And Adjusting
10. TESTING AND ADJUSTING 1. ENGINE SYSTEM EASE OF STARTING, NOISE Set gear shift lever at NEUTRAL. Forward Neutral Reverse 160D7OM45 Turn ON the parking brake switch. Turn ON start switch, automatically heat- ing operated. When heater signal lamp goes out, turn key to START, and start engine.
Page 240: Radiator Cap
The fuel filter element cannot be inspected from the outside, so replace it periodically (refer to page 7-13). Always use HYUNDAI Forklift genuine parts when replacing the element. After replacing the element, run the engine and check for oil leakage from the filter mount.
Page 241 Move fan backwards and forwards by hand to check for looseness. Tighten mounting bolt with a spanner. Crack 160D7TA11 10-3...
Page 242: Drive System
2. DRIVE SYSTEM GEAR SHIFT LEVER Neutral starting Engine can be started only when the shifting lever is in neutral position. Shifting FWD/REV lever ① ① Forward Push the lever forward then forward solenoid valve operates and oil comes to forward clutch thus the truck will run forward.
Page 243 Inching pedal ·Adjust stopper bolt(1) so that pedal angle is "H"(voltage : 1±0.1V). - Pedal angle(H) : 35。 ·When fully pedaled, voltage is controlled to 3.5±0.1V. ·Adjust bolt(3) so that brake pedal interconnects with inching pedal at inching pedal stroke, 22mm(0.9in). 160D7ETA05 10-5...
Page 244: Travel System
3. TRAVEL SYSTEM TIRES Check tire pressure using tire gauge : SEE page 5-3 CHECK BEFORE STARTING ENGINE. Check visually for cracks and damage to tread and side wall. If crack or damage is serious, replace tire. Wear Measure tread of pneumatic tires(tires with air).
Page 245: Steering System
4. STEERING SYSTEM STEERING WHEEL 30~60mm Set rear wheels facing straight forward, (1.2~2.4 in) then turn steering wheel to left and right. Measure range of steering wheel movement before rear wheel starts to move. Range should be 30 - 60mm at rim of steering wheel.

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