Hyundai HDF20-5 Manual
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Hyundai HDF20-5 Manual

Hyundai HDF20-5 Manual

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1. Daily inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
2. Do's and don'ts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-2
3. Seat belts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-4
4. No riders - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5
5. Pedestrians - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6
6. Operator protection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-7
7. Fork safety - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-8
8. Pinch points - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-9
9. Travel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-10
10. Grades, ramps, slopes and inclines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-11
11. Tip over - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-12
12. Surface and capacity - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-14
13. Parking - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-15
14. Refueling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-16
15. Step - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-17
16. Operator's safety rules - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-18
1. Loose loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
2. Long and wide loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
3. Rear swing - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2
4. Low overhead clearance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3
5. Fast turns and hiqh loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3
6. Drop-offs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4
7. Right angle stacking - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-4
8. Chain slack - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5
9. Pallets and skids - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-5
10. Caution for electrical lines - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6
11. Lifting loads - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-7
1. General locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
2. Data/safety plates and decals - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-4
3. Instruments and controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-7
4. Indicator symbols - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-10
5. Operating lever and switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-20
CONTENTS

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Summary of Contents for Hyundai HDF20-5

  • Page 1: Table Of Contents

    CONTENTS 1. SAFETY HINTS 1. Daily inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 2.
  • Page 2 4. OPERATOR MAINTENANCE AND CARE 1. Daily safety inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1 2.
  • Page 3 8. SPECIFICATIONS 1. Specification table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1 2.
  • Page 4 HYUNDAI lift trucks are built to take hard work, but not abuse. They are built to be dependable, but they are only as safe and efficient as the operator and the persons responsible for maintaining them. Do not make any repairs to this truck unless you have been trained in safe lift truck repair procedures and are authorized by your employer.
  • Page 5 HYUNDAI lift truck in a safe and correct manner. Your HYUNDAI lift truck has been designed and built to be as safe and efficient as today's technology can make it. As manufactured, for some models, it meets all the applicable mandatory requirements of ANSI B56.1-1988 Safety Standard for Powered Industrial Trucks.
  • Page 6 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: Machine Serial Number

    GUIDE 1. DIRECTION The directions of this machine indicate forward, Front backward, right and left when machine is in the travelling direction. Right Left Rear D255SM01 2. SERIAL NUMBER Inform following when you order parts or the machine is out of order. MACHINE SERIAL NUMBER It's shown on front of the right side frame.

  • Page 9: Safety Hints

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

  • Page 10: Do's And Don'ts

    2. DO'S AND DON'TS Do watch for pedestrians. D35AOM03 Do wear safety equipment when required. D35AOM05 Don't mix drugs or alcohol with your job. D35AOM02 Don't block safety or emergency equipment. D35AOM04 Don't smoke in NO SMOKING areas or when refueling. D35AOM06...
  • Page 11 Don't operate the truck outdoors in rainy day. xclude the truck equipped cabin. D35AOM07 Exhaust gas is dangerous. Do not operate the truck at the inhouse, if possible. Provide adequate ventilation when working in a closed space. D35AOM08...

  • Page 12: Seat Belts

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

  • Page 13: No Riders

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

  • Page 14: Pedestrians

    5. PEDESTRIANS Watch where you are going. Look in the direction of travel. Pedestrians may use the same roadway you do. Sound your horn at all intersections or blind spots. D35AOM13 Watch for people in your work area even if your truck has warning lights or alarms.

  • Page 15: Operator Protection

    6. OPERATOR PROTECTION Keep under the overhead guard. Always keep your body within the confines of the truck. Do not operate truck without overhead guard, unless condition prevent use of a guard. D35AOM16...

  • Page 16: 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. D255OM12A Always lower the load slowly. Raise and lower with mast vertical or tilted slightly back(Never forward).

  • Page 17: Pinch Points

    8. PINCH POINTS Keep hands, feet and legs out of the mast. D255OM61 Don't use the mast as a ladder. D255OM62 Never try to repair the mast, carriage, chain, or attachment by yourself. Always get a trained mechanic. D255OM63...

  • Page 18: Travel

    9. TRAVEL Travel with the load near the floor/ground, with mast tilted back to cradle the load whenever possible. Never lift or lower the load when the truck is in motion. D35AOM23 When handling bulky loads that restrict your vision operate your truck in reverse to improve visibility.

  • Page 19: Grades, Ramps, Slopes And Inclines

    10. GRADES, RAMPS, SLOPES AND INCLINES Never turn on a grade, either loaded or unloaded. Unloaded-Forks downgrade D255OM26A Loaded - Forks upgrade D255OM27A 1-11...

  • Page 20: Tip Over

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

  • Page 22: Surface And Capacity

    12. SURFACE AND CAPACITY Avoid these conditions. They can cause a truck to tip over or lose traction for braking or driving. Know the weight of your truck and load. Especially when using elevators, Know the capacity of the elevator you intend to use.

  • Page 23: Parking

    13. PARKING Never park on a grade. D35AOM33 Always come to a complete stop before leaving truck. Be sure travel control is in NEUTRAL. D35AOM34 Lower forks fully to floor and tilt forward. D255OM35A Set parking brake. Position 1 : Lock Position 2 : Release Turn key to OFF position.

  • Page 24: Refueling

    14. REFUELING Before adding oil, check around machine for oil leakage. D255OM02 Keep away from fire when adding oil or during operation. D255OM03 After adding oil, wipe off any oil spilled on machine. D255OM04 1-16...

  • Page 25: Step

    15. STEP When getting on or off the machine, use the step provided. D255OM05 Do not jump up or down from the machine. D255OM06 1-17...

  • Page 26: Operator's Safety Rules

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

  • Page 27: Operating Hazards

    2. OPERATING HAZARDS 1. LOOSE LOADS Loose or unbalanced loads are dangerous. Observe these precautions. Never carry loose or uneven material. D255OM39 Center wide loads. D35AOM40 Stack and band loose material. D35AOM41 Avoid sudden braking or starting When the machine is loaded, do not drive at maximum speed.

  • Page 28: 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 29: 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. B207OM44 Watch overhead clearance: Moving into overhead structures can tip a truck over, or spill a load. B207OM45 5.

  • Page 30: Drop-Offs

    6. DROP-OFFS To avoid these hazards, you must: Talk to the truck driver yourself: make sure the driver does not move the trailer until you are done. Apply trailer brakes. Use wheel chocks. Use trailer-to-dock locking system if available. D35AOM48 The impact of moving in and out of a trailer may cause the trailer to creep or move.

  • Page 31: Chain Slack

    8. CHAIN SLACK Slack chains mean rail or carriage hang- Raise the forks before you move, or broken chains can result. In case forks with loads are stuck while lowering the mast, lift the mast again and prevent chains from being slack. D35AOM51 D35AOM52 9.

  • Page 32: Caution For Electrical Lines

    10. CAUTION FOR ELECTRICAL LINES When moving the machine with the mast raised, watch out electrical lines over the machine. The operating near the electrical lines is very dangerous. Operate within safe working permitted as below. Supply voltage Min safe separation D255SF01 6.6 kV 3m (10ft)

  • Page 33: Lifting Loads

    11. LIFTING LOADS Never permit any persons to stand or pass under lifted load. D255OM08 Never use wire rope to lift a load. D255OM09...

  • Page 34: Know Your Truck

    3. KNOW YOUR TRUCK 1. GENERAL LOCATIONS HDF15/18-5, HDF20/25/30-5 D155OM54 Mast Forks 13 Counterweight Lift chain Overhead guard 14 Rear wheel Lift cylinder Turn signal lamp 15 Front wheel Backrest 10 Head lamp 16 Rear combination lamp Tilt cylinder 11 Operator's seat Lift bracket 12 Bonnet...
  • Page 35 35D/40D/45D-7, 35DS/40DS/45DS-7 D357OM54 Mast Forks 13 Counterweight Lift chain Overhead guard 14 Rear wheel Lift cylinder Turn signal lamp 15 Front wheel Backrest 10 Head lamp 16 Rear combination lamp Tilt cylinder 11 Operator's seat Lift bracket 12 Bonnet...
  • Page 36 HDF50/70-7S, HDF50/70-7 D507OM54 Mast Forks 13 Counterweight Lift chain Overhead guard 14 Rear wheel Lift cylinder Turn signal lamp 15 Front wheel Backrest 10 Head lamp 16 Rear combination lamp Tilt cylinder 11 Operator's seat Lift bracket 12 Bonnet...

  • Page 37: Data/Safety Plates And Decals

    Truck serial number An identification number assigned to this particular truck and should be used when requesting information or ordering service parts for this truck from your authorized HYUNDAI dealer. The serial number is also stamped on the frame. Attachment description(If any installed) The user must see that the truck is marked to identify the attachment(s), including the weight of the truck/attachment combination and truck capacity with the attachment.
  • Page 38 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! D35AOM59 Safety and warning decals are placed in conspicuous locations on the AVOID: truck to remind you of essential procedures or to prevent you from slippery,...
  • Page 39 Mast warning decal This safety decal is placed on the mast to warn of the danger of injury from movement between rails, chains, sheaves, fork carriage, and other parts of the mast assembly. Do not climb on or reach into the mast.

  • Page 40: Instruments And Controls

    3. INSTRUMENTS AND CONTROLS HDF15/18-5, HDF20/25/30-5 29 30 31 DETAIL A HDF15/18-5 ONLY 16, 17, 18 HDF15/18-5 ONLY 25 26 10 11 D155OM64 Start switch 12 Work lamp signal lamp 23 Brake pedal Fuel gauge 13 Left turn signal lamp 24 Inching pedal Hour meter 14 Right turn signal lamp...
  • Page 41 35D/40D/45D-7, 35DS/40DS/45DS-7 28, 29, 30 3 4 5 8 9 10 11 0 0 0 0 HYUNDAI 0 0 0 0 HYUNDAI 15 16 17 18 19 23 2425 26 DETAIL A D357OM64T Start switch 16 Water separator lamp* 30 Turn signal switch...
  • Page 42 HDF50/70-7S, HDF50/70-7 DETAIL A 23 24 25 26 27 20, 21,22 28 29 30 31 HYUNDAI 7 8 9 10 11 12 13 14 15 DETAIL B D507OM64T Start switch 14 Work lamp signal lamp 27 Attach 2 lever(opt) Water temperature gauge...

  • Page 43: Indicator Symbols

    4. INDICATOR SYMBOLS FUEL GAUGE E : Empty F : Full Fill fuel tank regularly. Never allow machine to run out fuel. Do not overfill the fuel tank. Always check the fuel level on level ground. D155OM01 3.5~4.5 ton only D357OM01T HOUR METER This indicates the time of total machine operation.

  • Page 44: Engine Oil Pressure Warning Lamp

    RANSMISSION OIL TEMPERATURE GAUGE(5.0TON~7.0TON) This range indicates the temperature of transmission oil. Green range : 50-120 C(122-248 F) Red range : 120 C(248 F) Above The green range indicates when operating. Keep idling engine at low speed until the green range 7303CCD12 indicates, before operation of machine.

  • Page 45: Battery Charge Warning Lamp

    BATTERY CHARGE WARNING LAMP This lamp shows that the alternator is not generating electricity. hen the starting switch is turned ON, the lamp will lights up, but it should go out after the engine starts. If the lamp lights up during operation, stop the engine and check the fan belt tension and the electrical system.
  • Page 46 WORKING LAMP SIGNAL LAMP This lamp shows that the working lamp lights up or not. Working lamp lights up : Signal lamp lights up. Working lamp goes out : Signal lamp goes out. D35AOM86 LEFT TURN SIGNAL LAMP Left turn signal lamp flickers when pushing on the turn signal lever.
  • Page 47 ENGINE CHECK LAMP(35D/40D/45D-7(#1001-), HDF50/70-7(#1001-)) This lamp lights ON during a nonfatal engine system error. The engine can steel be run, but the fault should be corrected as soon as possible. D357OM904T OPERATOR SAFETY LAMP (35DS/40DS/45DS-7, OPSS equipped) This signal lamp lights ON when the operator leaves the seat. Powered travel movement of the truck shall be possible only if the operator is in the normal operating position.
  • Page 48 TRANSMISSION ERROR DISPLAY(HDF50/70-7S, HDF50/70-7 : ZF Transmission) Function The display can be used with the gear selector(DW-3). It indicates speed and driving direction as well as the activated kickdown. When driving in the automatic mode, a bar indicator gives additionally also information about the selected driving range;...
  • Page 49 isplay during operation Symbol Meaning Remarks Actual gear and direction F, N, R Central side shows actual gear 1, 2, 3 Right side shows actual direction Not neutral, waiting for neutral To engage a gear, first move shift selector to (Central and right side) after power up or a severse fault neutral position and again to F to R position...
  • Page 50 Definition of the error codes Introduction The error codes consists of two hexadecimal numbers. The first number shows the type of signal, the second number shows signal and the type of the error. Description of error codes First No. Meaning of number 1 hex Digital input signals 2 hex...
  • Page 51 Number Meaning of error code 3A hex Short circuit to battery voltage or open circuit at output speed input 3B hex Short circuit to ground or open circuit at output speed input 3C hex Logical error at output speed input 71 hex Short circuit to battery voltage at clutch K1 72 hex...
  • Page 52 Number Meaning of error code Slippage at clutch K1 B1 hex B2 hex Slippage at clutch K2 B3 hex Slippage at clutch K3 B4 hex Slippage at clutch K4 Slippage at clutch KV B5 hex Slippage at clutch KR B6 hex D1 hex Short circuit to battery voltage at power supply for sensors D2 hex...

  • Page 53: Operating Lever And Switch

    5. OPERATING LEVER AND SWITCH START SWITCH There are four positions, HEAT, OFF, ON and START. Before starting, set gear shift lever at N, and pull parking brake. HEAT : Preheating electrical circuit activates. - HDF15/18-5 - 35D/40D/45D-7(-#1000) - HDF50/70-7(-#1000) D255OM10 : None of electrical circuits activates.
  • Page 54 HAZARD SWITCH Use for parking, or loading machine. If the switch is left ON for a long time, the battery may be discharged. L255OM17 WORK LAMP SWITCH This switch is used to operate work lamps. Press this switch to turn on work lamps. 5.0 ~ 7.0 ton : Standard 1.5 ~ 4.5 ton : Option L255OM16...

  • Page 55: Turn Signal Switch

    HEATER SWITCH(HDF50/70-7S, HDF50/70-7 OPTION) Heater runs when this switch is pressed. Heater level can be adjusted by 2 steps. 0 : Stop : 1st level 2 : 2nd level D507CD61 WIPER SWITCH(HDF50/70-7S, HDF50/70-7 OPTION) Machine with cabin offers this switch. Wiper operates when this switch is pressed.

  • Page 56: Horn Button

    HORN BUTTON The horn sounds when the button is depressed. 1.5 ~ 4.5 ton 5.0 ~ 7.0 ton D507OM97 OOM LAMP(HDF50/70-7S, HDF50/70-7, OPTION) This switch is located on the ceiling of the cabin. (For machine with cabin) ON : Room lamp lights on : Room lamp lights on automatically only when door opens.
  • Page 57 LIFT LEVER Lift Lower PULL the lever BACK to LIFT the load. LOWER PUSH the lever FORWARD to LOWER the load. HOLDING D507OM17 When the lever is released, the lifting or lowering action stops. Lifting speed is controlled by accelerator pedal. Lowering speed is controlled by lever only.
  • Page 58 BONNET DF15/18-5, HDF20/25/30-5 1.5~3.0 ton 1.5~3.0 ton Unlock latch with a key and then raise engine hood to open Engine hood Inspection and maintenance can then be carried out easily. Unlock latch 3.5~4.5 ton 35DS/40DS/45DS-7, 35D/40D/45D-7 3.5~4.5 ton Unlock latch with a key and then raise engine hood to open Engine hood Inspection and maintenance can then be carried out easily.

  • Page 59: 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 60: 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 61: Fuel Safety Practices

    2. FUEL SAFETY PRACTICES REFUELING DIESEL TRUCKS 1.5~3.0 ton 3.5~8.0 ton 80D7OM106 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 62: 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 63: Check Before Starting

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

  • Page 64: Check Before Starting Engine

    3. CHECK BEFORE STARTING ENGINE CHECK FOR WATER OR OIL LEAKAGE Walk around your HYUNDAI truck and check for water, oil or hydraulic leakage. Examine truck for obvious damage. Check overhead guard, backrest and forks for crack or obvious damage.

  • Page 65: Check Brake Fluid

    CHECK BRAKE FLUID Remove reservoir cap, and check level. If necessary, add brake fluid. Normal 25-45 mm Model Brake fluid (1-1.8 in) 1.5~3.0 ton, 5.0~7.0 ton DOT III (DRY) D35AOM110 3.5~7.0 ton Azola ZS10 or hyd oil SAE 10W(WET) CHECK COOLANT LEVEL If the cooling water in the radiator sub-tank is not within normal range when cool, add water to the MAX line.

  • Page 66: Check Hydraulic Oil Level

    CHECK FAN BELT TENSION The fan belt must depress the specified value when the midpoint between the generator and fan pulley is depressed. If the belt is stretched beyond the adjustment allowance, or there are cuts or cracks, replace the V-belt. HDF15/18-5 : 7~9mm(0.28~0.35in) D35AOM113...

  • Page 67: Check Parking Brake

    1 : Horn button (1.5~4.5 ton) 1' : Lamp switch (1.5~4.5 ton) 2 : Horn button (5.0~7.0 ton) 5.0 ~ 7.0 ton 5.0~8.0ton 2' : Lamp switch (5.0~7.0 ton) If horn and lamp are malfunctioning, contact your HYUNDAI forklift distributor. D507OM13...
  • Page 68 CHECK PEDALS Check for any catching or abnormal heaviness when depressing the pedals. Inching pedal Unit 1.5 ~ 1.8 ton 2.0 ~ 3.0 ton 3.5 ~ 4.5 ton 5.0 ~ 7.0 ton 13~18 4~6.5 Free play (in) (0.39) (0.08~0.16) (0.5~0.7) (0.16~0.26) Interlock stroke 35~45...

  • Page 69: Seat Adjustment

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

  • Page 70: Starting From A Safe Condition

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

  • Page 71: 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 72: Starting The Engine

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

  • Page 73: Check After Starting Engine

    8. CHECK AFTER STARTING ENGINE CHECK FOR ABNORMAL NOISE OR VIBRATION CHECK ENGINE EXHAUST COLOR Exhaust gas color Criteria Colorless, light blue Black Check for incomplete combustion White Check for oil leakage CHECK FUEL TANK LEVEL(DIESEL TYPE) If the indicator points to F, the tank is full. If the indicator enters the E range, refill the fuel tank immediately.
  • Page 74 HECK STEERING WHEEL PLAY If the steering wheel play is over 30~60mm (1.2-2.4in), check or 30-60mm repair it. (1.2-2.4 in) D35AOM127 CHECK LIFT CHAIN TENSION Raise forks 10 to 15cm(4 to 6in) from ground. Push with a rod check that both chains have approximately same amount of slack.

  • Page 75: 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 76 SELECTING DIRECTION OF TRAVEL Push the direction control lever forward, center it , or pull it back for FORWARD, NEUTRAL, or REVERSE, respectively. Traction is disabled in NEUTRAL. Reverse Forward D507OM95 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 77: Operating Safely

    10. OPERATING SAFELY Safe operation is the responsibility of the operator. WATCH WHERE YOU ARE GOING. DON’T GO IF YOU CAN’T SEE... Before driving, check all around to be sure that your intended path of travel is clear of obstructions and pedestrians.
  • Page 78 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 79: Load Handling

    11. LOAD HANDLING GENERAL Handle only loads that are within the truck rated capacity as shown on the nameplate. This rating specifies the maximum load that should be lifted. However, other factors such as special load handling attachments, load having a high center of gravity, or uneven terrain may dictate that the safe working load be less than the rated capacity.
  • Page 80 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 81 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 82 STACKING To put a load on a stack Aproach slowly and align the lift truck and load squarely with the stack. D35AOM137 Raise the load as the lift truck nears the stack. D35AOM138 Move forward slowly until the load almost touches the stack. The leading edge and sides of the load pallet should line up exactly with the near edge and side of the load or rack on which you are stacking.
  • Page 83 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 84: Shut Down Procedure

    1 1 2. SHUT DOWN PROCEDURE Always leave your lift truck in a safe condition. WHEN YOU LEAVE YOUR TRUCK, OR PARK IT, FOLLOW THESE SAFELY RULES Park in a safe area away from normal traffic. Never park on a grade. Never park in areas that block emergency routes or equipment, access to fire aisles, or stairways and fire equipment.

  • Page 85: 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 86 Park the disabled truck in authorized areas only. Fully lower the forks to the floor, put the directional control lever in the NEUTRAL position and turn the staring switch to the OFF position. Engage the parking brake. Remove the key and, when necessary, block the wheels to prevent the truck from rolling.

  • Page 87: How To Use Battery Jumper Cables

    2. HOW TO USE BATTERY JUMPER CABLES If your lift truck battery is discharged(dead), you can start your lift truck by Jumping it from another lift truck that has a 12V(1.5~3.0Ton) or 24V(3.5~7.0Ton), negative-ground electrical system. The "Booster" battery must be fully charged and in good condition. This section explains how to perform this procedure safely.
  • Page 88 Connect the jumper cables in the following To ground To start switch sequence: 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 89: Planned Maintenance And Lubrication

    In addition to the operator's daily inspection, HYUNDAI recommends that the owner set up and follow a periodic planned maintenance(PM) and inspection program. Performed on a regular basis by trained personnel, the program provides through truck.

  • Page 90: 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 91 Before leaving the truck. Stop the truck. Fully lower the load-engaging means: mast, carriage, forks or attachments. Put the directional control in NEUTRAL. Apply the parking brake. Stop the engine. Turn the key switch to the OFF position. Put blocks at the wheels if the truck must be left on an incline. Brakes, steering mechanisms, control mechanisms, warning devices, lights, governors, lift overload devices, lift and tilt mechanisms, articulating axle stops, load backrest, overhead guard and frame members must be carefully and regularly inspected and maintained in a safe operating condition.
  • Page 92 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 93: 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 HOUR METER 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 94: 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 95 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 recommend replacement interval. Replacement of consumable service parts is not covered under warranty. Periodical replacement of safety parts Interval Every 2 to 4 years...

  • Page 96: Planned Maintenance Intervals

    4. PLANNED MAINTENANCE INTERVALS MAJOR COMPONENT LOCATIONS HDF15/18-5, HDF20/25/30-5 D155OM21 Mast Transmission 15 Muffler Lift cylinder Torque converter 16 Counterweight Tilt cylinder 10 Engine 17 Radiator Control valve 11 Steering cylinder 18 Operator's seat Fork 12 Hydraulic pump 19 Overhead guard Front wheel 13 Steering axle(Rear) 20 Steering wheel...
  • Page 97 35DS/40DS/45DS-7, 35D/40D/45D-7 10 11 12 13 15 16 17 D357OM21 Mast 10 Transmission 19 Muffler Lift cylinder 11 Torque converter 20 Silencer Steering unit 12 Engine 21 Overhead guard Tilt cylinder 13 Exhaust pipe 22 Seat Control valve 14 Air cleaner 23 Control lever Fork 15 Steering axle...
  • Page 98 HDF50/70-7S, HDF50/70-7 8 9 10 11 12 13 14 15 16 17 D507OM21 Mast 10 Priority valve 19 Muffler Lift cylinder 11 Transmission 20 Silencer Tilt cylinder 12 Torque converter 21 Air cleaner Control valve 13 Engine 22 Overhead guard Fork 14 Exhaust pipe 23 Seat...

  • Page 99: Every 50 Hours Service

    MAINTENANCE CHECK LIST EVERY 10 HOURS SERVICE Check items Service Remarks Visual inspection Truck for obvious damage and leaks. Check, Repair or Replace Warning plates and decals. 3-4 ~ 3-6 Check, Replace 5-3, 7-19 Condition of tires and wheels. Air pressure. Check, Refill or Replace 7-34, 7-35 Lift chain and fastener.

  • Page 100: Every 250 Hours Service

    INITIAL 100 HOURS SERVICE Check items Service Remarks Differential gear oil Change 7-23 Transmission oil and filter Replace 7-23 Drive axle cooling oil Change EVERY 250 HOURS SERVICE Check items Service Remarks 7-22 Engine oil* Check, Replace 7-23 Differential gear oil Check, Refill Lubrication 7-33...

  • Page 101: When Required

    WHEN REQUIRED Check items Service Remarks Fuel system 5-12 Fuel tank Drain or Clean Water separator Drain or Clean 7-22 Fuel filter Replace Engine lubrication system 7-22 Engine oil Replace 7-22 Engine oil filter cartrige Replace Engine cooling system 7-31 Coolant Refill, Replace 7-25...

  • Page 102: Maintenance Locations

    5 5 . MAINTENANCE CHART MAINTENANCE LOCATIONS D357MA01 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. Open the cap slowly to relieve pressure.

  • Page 103: Maintenance Chart

    MAINTENANCE CHART HDF15/18-5, HDF20/25/30-5 Capacity( ) Service Item Service Service Description interval Action symbol point No. 1.5~1.8ton 2.0~3.0ton Tilt pin & Mast roller Check, Add Lift chain Check, Add Brake oil Check, Add Parking brake operation Check, Adjust Hydraulic oil level Check, Add Engine oil level Check, Add...
  • Page 104 35D/40D/45D-7, 35DS/40DS/45DS-7 Capacity( ) Service Item Service Service Description interval Action symbol point No. HMC ENG MHI ENG Tilt pin & Mast roller Check, Add Check, Add Lift chain Check, Add Brake oil Parking brake operation Check, Adjust Check, Add Hydraulic oil level Engine oil level Check, Add...
  • Page 105 HDF50/70-7S, HDF50/70-7 Capacity( ) Service Item Service Service Description interval Action symbol point No. MHI ENG HMC ENG Check, Add Tilt pin & Mast roller Check, Add Lift chain Check, Add Brake oil Check, Adjust Parking brake operation Check, Add Hydraulic oil level Check, Add 17.5...

  • Page 106: 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 107: Wheel And Tires

    FORKS Inspect the load forks for cracks, breaks, bending, and wear. The fork top surfaces should be level 10% of "A" is and even with each other. The height difference max wear allowed between both fork tips should be no more than 3% of the fork length.

  • Page 108: Replacement And Check

    7. REPLACEMENT AND CHECK 7. REPLACEMENT AND CHECK Check the battery condition per the table below. Add water, or recharge as shown by the indicator. Battery indicator Battery condition Mark Color Normal Green Insufficient distilled water White Insufficient charge BATTERIES EMIT EXPLOSIVE GAS. Do not BATTERIES EMIT EXPLOSIVE GAS.

  • Page 109: 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 it when the cables possess any kind of it when the cables possess any kind of Neg(-) abnormal damages such as cracking and wear...
  • Page 110 OSHA approved eye protection rated for 200kPa(30psi) is required for air cleaning operation. 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 Replace element if exhaust is black, or if lack of engine power is noted even after cleaning or element.

  • Page 111: Transmission Oil

    TRANSMISSION OIL 1.5~3.0 ton HDF15~30-5 Do not touch hot components or allow hot oil to Dipstick contact your skin. Normal Cold Transmission oil Park the truck in a level place and lower the forks. Then stop the engine and apply the Drain plug parking brake.

  • Page 112: 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. HDF20/25/30-5 HDF15/18-5 Drain Drain plug plug D507OM28 D507OM28-1 35DS/40DS/45DS-7...

  • Page 113: 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 114: Fuses Replacement

    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 115 5DS/40DS/45DS-7, 35D/40D/45D-7 Capacity Color Related electrical component REGU HEAD TURN ENG STOP HORN LATOR SWITCH PANEL LAMP LAMP MOTOR Regulator F-R switch OP panel SPARE(10A) SPARE(10A) SPARE (15A) Green Head lamp STOP WORK ALTER ENG STOP OPTION LAMP LAMP NATOR RELAY HOLDER Turn lamp...

  • Page 116: Functional Tests

    LAMP BULBS REPLACEMENT Lamp Spec(for 12V) Spec(for 24V) Head lamp Turn signal lamp Clearance lamp Stop lamp Backup lamp Warning lamp 1.4W Meter lighting lamp 3.4W D507OM14 License lamp (option) 3.4W 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 117 Indicator lights Check that all lights are functioning and indicate normal truck operation as described in section 3, Know your truck, in this manual. Service brakes and inching pedal With the direction control in NEUTRAL and the engine running, push the sevice brake pedal fully down and hold.
  • Page 118 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 119 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 120 OIL PERFORMANCE DESIGNATION: To help achieve proper engine performance and durability, use only engine lubricating oils of the proper quality. For LPG and diesel engines, HYUNDAI recommends that you use motor oil that meets API service classification CD, CC/SG, SF and API CH4 SAE 15W-40 for diesel engines, gas engines use API SG, SAE 10W-30 oil or better.

  • Page 121: 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 122 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 123 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 124: Lubrication Chart

    8. LUBRICATION CHART DF15/18-5, HDF20/25/30-5 LIFT CHAIN GEAR OIL LIFT TRANSMISSION SUPPORT BRAKE FLUID HYDRAULIC RESERVOIR OIL TANK ENGINE OIL PAN LINKAGE KING PIN Check everyday Every two weeks(100 hours) Every month(250 hours) Every 3 month(600 hours) Every 6 month(1200 hours) D255LUB01 NOTES : Check, add oil when needed.
  • Page 125 35DS/40DS/45DS-7, 35D/40D/45D-7 LIFT CHAIN GEAR OIL TRANSMISSION LIFT SUPPORT BRAKE FLUID ENGINE RESERVOIR OIL PAN LINKAGE HYDRAULIC KING PIN OIL TANK Check everyday Every two weeks(100 hours) Every month(250 hours) Every 3 month(600 hours) Every 6 month(1200 hours) D357LUB01 NOTES : Check, add oil when needed.
  • Page 126 HDF50/70-7S, HDF50/70-7 LIFT CHAIN GEAR OIL TRANSMISSION LIFT SUPPORT BRAKE FLUID ENGINE RESERVOIR OIL PAN LINKAGE HYDRAULIC KING PIN OIL TANK Check everyday Every two weeks(100 hours) Every month(250 hours) Every 3 month(600 hours) Every 6 month(1200 hours) D507LUB01 NOTES : Check, add oil when needed.

  • Page 127: Greasing Point

    9. GREASING POINT HDF15/18-5, HDF20/25/30-5 Lift chain(coated with engine oil) Steering axle Tilt cylinder Fork stopper Pedal pin Adjust bolt Mast support D255OM172 35DS/40DS/45DS-7, 35D/40D/45D-7 Lift chain(coated with engine oil) Steering axle Tilt cylinder Fork stopper Adjust bolt Pedal pin Mast support D357OM172 7-39...
  • Page 128 HDF50/70-7S, HDF50/70-7 Lift chain(coated with engine oil) Steering axle Tilt cylinder Fork stopper Adjust bolt Pedal pin Mast support D507OM173 7-40...

  • Page 129: Handling Machine In Extremely Hot Places

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

  • Page 130: Cold Weather Operation

    11. 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 Amount of...

  • Page 131: Storage

    12. STORAGE BEFORE STORAGE When you keep your forklift truck in storage for an extended period of time, observe the following safeguard instruction: Wash and tidy the truck and house it in a dry building. When the truck has to be placed outdoors, park it on a even ground and cover it securely with canvas.

  • Page 132: Transport

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

  • Page 133: Loading And Unloading By Crane

    14. LOADING AND UNLOADING BY CRANE Check the weight, length, width and height of the 1.8 ~ 4.5 TON truck referring to the chapter 8, specifications Wire rope when you are going to hoist the truck. Stay Use long wire rope and stay to keep the distance with the machine as it should avoid touching with To mast the truck body.

  • Page 134: Recommendation Table For Lubricants

    15. RECOMMENDATION TABLE FOR LUBRICANTS NEW MACHINE New machine uses following fuel, coolant and lubricant. DF15/18-5, HDF20/25/30-5 Description Specification Engine oil SAE 10W-30/15W-40(API CH4 class or better) T/M oil ATF DEXRON III Gear oil SAE 80W-90/API GL-5 Hydraulic oil ISO VG32/VG46/VG68 Brake oil DOT 3 Grease...

  • Page 135: Fuel And Lubricants

    16. FUEL AND LUBRICANTS HDF15/18-5, HDF20/25/30-5 Capacity (U.S.gal) Ambient temperature Service Kind of point fluid 1.5~1.8ton 2.0~3.0ton (-4) (14) (32) (50) (68) (86) (104) SAE 30 SAE 10W Engine oil Engine oil (2.5) (1.9) SAE 10W-30 SAE 15W-40 Torque converter ATF DEXRON III (1.8) (2.6)
  • Page 136 35DS/40DS/45DS-7, 35D/40D/45D-7 Ambient temperature ¡£ C ( ¡£ F) Service Kind of Capacity§⁄ (U.S.gal) point fluid (-4) (14) (32) (50) (68) (86) (104) SAE 30 MMC : 17.5(4.6) SAE 10W Engine oil Engine oil HMC : 8.5(2.2) SAE 10W-30 SAE 15W-40 Torque converter T/M oil...
  • Page 137 HDF50/70-7(S)(DRY + WET) Ambient temperature Service Kind of Capacity point fluid (U.S.gal) (-4) (14) (32) (50) (68) (86) (104) SAE 30 SAE 10W Engine oil 17.5 Engine oil (4.6) SAE 10W-30 SAE 15W-40 Torque 15.6 converter Engine oil SAE 10W-30 (4.1) transmission 12.5...

  • Page 138: Specifications

    8. SPECIFICATIONS 1. SPECIFICATION TABLE HDF15/18-5 C' C D155SP01 Model Unit HDF 15-5 HDF 18-5 Capacity 1500 1750 Load center Weight(Unloaded) 2818 2998 Lifting height 3300 Free lift Lifting speed(Unload/Load) 650/590 650/580 Fork mm/sec Lowering speed(Unload/Load) 450/500 mm/sec L W T L,W,T 900 100 35 Tilt angle (forward/backward)
  • Page 139 HDF20/25/30-5 C' C D255SP01 Model Unit HDF 20-5 HDF 25-5 HDF 30-5 Capacity 2000 2500 3000 Load center Weight(Unloaded) 3695 3995 4460 Lifting height 3300 Free lift Lifting speed(Unload/Load) 690/670 580/530 Fork mm/sec Lowering speed(Unload/Load) 450/500 mm/sec L W T L,W,T 1050 100 45 1050 125 45...
  • Page 140 35DS/40DS/45DS-7 (MHI ENGINE) D357SP01 Model Unit 35DS-7 40DS-7 45DS-7 Capacity 3500 4000 4500 Load center Weight(Unloaded) 5915 6460 6875 Lifting height 3000 Free lift Lifting speed(Unload/Load) 600/570 600/560 600/550 Fork mm/sec Lowering speed(Unload/Load) 450/500 mm/sec L W T L,W,T 1070 122 50 1070 150 50 1220 150 50 Tilt angle (forward/backward)
  • Page 141 35D/40D/45D-7 (HMC ENGINE) D357SP01 Model Unit 35D-7 40D-7 45D-7 Capacity 3500 4000 4500 Load center Weight(Unloaded) 5890 6460 6875 Lifting height 3000 Free lift Lifting speed(Unload/Load) 600(570)/550 600(570)/540 600(570)/530 Fork mm/sec Lowering speed(Unload/Load) 450/500 mm/sec L W T L,W,T 1070 122 50 1070 150 50 1220 150 50 Tilt angle (forward/backward)
  • Page 142 HDF50/70-7S (MHI ENGINE) D507SP01 Model Unit HDF 50-7S HDF 70-7S Capacity 5000 7000 Load center Weight(Unloaded) 8347 9680 Lifting height 3000 Free lift Lifting speed(Unload/Load) 500/470 500/450 Fork mm/sec Lowering speed(Unload/Load) 450/500 mm/sec L W T L,W,T 1200 150 60 1200 180 60 Tilt angle (forward/backward) 15/10...
  • Page 143 HDF50/70-7 (HMC ENGINE) D507SP01 Model Unit HDF 50-7 HDF 70-7 Capacity 5000 7000 Load center Weight(Unloaded) 8321(8598) 9682(9839) Lifting height 3000 Free lift Lifting speed(Unload/Load) 500(450)/450(430) 500(450)/430(410) Fork mm/sec Lowering speed(Unload/Load) 450/500 mm/sec L W T L,W,T 1200 150 60 1200 180 60 Tilt angle (forward/backward) 15/10...

  • Page 144: Main Control Valve

    2 2 . SPECIFICATION FOR MAJOR COMPONENTS HDF15/18-5 ENGINE Item Specification Unit Model KUBOTA V2203-M Type 4-cycle, in-line overhead valve Cooling Method Water cooling Number of cylinders and arrangement 4 cylinders, in line Firing order 1-3-4-2 Combustion chamber type In direct injection Cylinder bore X stroke mm(in) 87 92.4(3.4...
  • Page 145 POWER TRAIN DEVICES Item Specification Model Z80-D1(KOREA POWERTRAIN) Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.8 : 1 Type Power shift Gear shift(FR/RR) Transmission Adjustment Electrical single lever type, kick-down system 13.720 : 1 Overhaul ratio 14.090 : 1 Type Front-wheel drive type, fixed location...
  • Page 146 HDF20/25/30-5 ENGINE Item Specification Unit Model YANMAR 4TNE98-HYF(IDI) Type 4-cycle, in-line overhead valve Cooling Method Water cooling Number of cylinders and arrangement 4 cylinders, in-line Firing order 1-3-4-2 Combustion chamber type In-direct injection mm(in) Cylinder bore X stroke 98 110(3.9 4.3 Piston displacement cc(cu in) 3319(202.5)
  • Page 147 POWER TRAIN DEVICES Item Specification Model Z80-D1(KOREA POWERTRAIN) Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio Type Power shift Gear shift(FR/RR) Transmission Adjustment Electrical single lever type, kick-down system 16.028 : 1 Overhaul ratio 18.317 : 1 Type Front-wheel drive type, fixed location Axle...
  • Page 148 35DS/40DS/45DS-7 ENGINE Item Specification Unit Model MITSUBISHI S6S-DT Type 4-cycle, in-line, Vertical OHV 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 94 120(3.7 4.7) Piston displacement cc(cu in) 4996(305)
  • Page 149 POWER TRAIN DEVICES Item Specification Model DE 280 (KAPEC) Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.25 : 1 Type Power shift Gear shift(FR/RR) Transmission Adjustment Electrical single lever type 1 : 2.550 2 : 1.151 Overhaul ratio 1 : 2.550 2 : 1.151...
  • Page 150 35D/40D/45D-7 ENGINE Item Specification Unit Model HYUNDAI D4DA-C1 **D4DD-C1 Type 4 cycle turbocharged diesel type Cooling Method Water cooling Number of cylinders and arrangement 4 cylinders, In-line Firing order 1-3-4-2 Combustion chamber type Direct injection mm(in) Cylinder bore X stroke 104 115(4.1 4.5)
  • Page 151 POWER TRAIN DEVICES Item Specification Model DE 280 (KAPEC) Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.25 : 1 Type Power shift Gear shift(FR/RR) Transmission Adjustment Electrical single lever type 1 : 2.550 2 : 1.151 Overhaul ratio 1 : 2.550 2 : 1.151...
  • Page 152 HDF50/70-7S ENGINE Item Specification Unit Model MITSUBISHI S6S-DT Type 4-cycle, in-line, Vertical OHV Cooling Method Water cooling Number of cylinders and arrangement 6 cylinders, in line Firing order 1-5-3-6-2-4 Combustion chamber type In direct injection mm(in) Cylinder bore X stroke 94 120(3.7 4.7) Piston displacement cc(cu in)
  • Page 153 POWER TRAIN DEVICES Item Specification Model F&S 300*16/4/-1(ZF SACH) Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.5 : 1 Type Full auto, Power shift Gear shift(FR/RR) Transmission Adjustment Electrical single lever type 1 : 4.578 2 : 2.396 3 : 0.994 Overhaul ratio 1 : 4.593...
  • Page 154 HDF50/70-7 ENGINE Item Unit Specification Model HYUNDAI D4DA-C2 *D4DD-C2 Type 4 cycle turbocharged diesel type Cooling Method Water cooling Number of cylinders and arrangement 4 cylinders, In-line Firing order 1-3-4-2 Combustion chamber type Direct injection mm(in) Cylinder bore X stroke 104 115(4.1 4.5)
  • Page 155 POWER TRAIN DEVICES Item Specification Model F&S 300*16/4/-1(ZF SACH) Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.5 : 1 Type Full auto, Power shift Gear shift(FR/RR) Transmission Adjustment Electrical single lever type 1 : 4.578 2 : 2.396 3 : 0.994 Overhaul ratio 1 : 4.593...

  • Page 156: Tightening Torque

    3. TIGHTENING TORQUE HDF15/18-5 kgf m lbf ft Item Size Engine mounting bolt, nut Engine Radiator mounting bolt, nut 2.5 0.5 18.1 3.6 M 8 1.25 Torque converter mounting bolt 4.17 M 8 1.25 Hydraulic MCV mounting bolt, nut 7.43 1.5 54 10.8 M10 1.25 system...
  • Page 157 5DS/40DS/45DS-7, 35D/40D/45D-7 Item Size kgf m lbf ft Engine mounting bolt, nut M16 2.0 Engine Radiator mounting bolt, nut 6.9 1.4 50 10 M10 1.5 Torque converter mounting bolt 6.9 1.4 50 10 M10 1.5 MCV mounting bolt, nut 19.6 2.9 142 21 M14 2.0 Hydraulic...

  • Page 158: 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 159: 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 does not light du Charge lamp defective.
  • Page 160 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 161 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. Oil filter clogging. Check and replace Oil pump worn.
  • Page 162 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 163 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 164: 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 165: 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. Lining surface soiled with water or oil. Clean or replace. Lining surface roughened or in poor Repair by polishing or replace.
  • Page 166 Trouble symptom robable cause Remedy 5. Brake squeaks Lining poor contact with drum. Repair or replace. (continue) Anti-rattle spring poorly installed. Repair or replace. 6. Brake rapping Drum sliding surface roughened. Repair by polishing or replace. Drum eccentric or excessively distort- Replace.

  • Page 167: 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 168: Testing And Adjusting

    10. TESTING AND ADJUSTING 1. ENGINE SYSTEM EASE OF STARTING, NOISE Set gear shift lever at N, and pull parking brake. Turn start switch ON. Turn start switch to HEAT. (A) When heater signal lamp goes out, turn key to START, and start engine. When engine starts, check if it starts smoothly, and if it makes any abnormal D507OM10...
  • Page 169 WHEN ACCELERATOR PEDAL IS DEPRESSED Check that accelerator pedal does not catch when depressed. Check that engine speed increases in accordance with amount pedal is depressed. When doing this, check that engine speed changes without gasping, abnormal noise, abnormal explosions, or irregular vibration. Check that exhaust gas is colorless when the engine is idling, and a thin black color when accelerator pedal is depressed.

  • Page 170: Radiator Cap

    The fuel filter element cannot be inspected from the outside, so replace it periodically. (Refer to 7.PLANNED MAINTENANCE AND LUBRICATION) Always use HYUNDAI Forklift genuine parts when replacing the element. After replacing the element, run the engine and check for oil leakage from the filter mount.
  • Page 171 FAN BELT Check that fan belt is not damaged. Alt. Check inside of belt also. If bottom of pulley pulley pulley groove is shining, belt will slip so replace. Check deflection when fan belt is pushed with a finger pressure at a point midway between fan pulley and alternator pulley.

  • Page 172: 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 Forward Push the lever forward then forward solenoid valve operates and oil comes to forward clutch thus the truck will run forward.
  • Page 173 Brake pedal Adjust stopper bolt(1) so that pedal height is "H". Adjust push rod(2) so that pedal play is idle stroke. Unit:mm Model IDLE 1.5~1.8 ton 130~140 2.0~3.0 ton 160~170 10~15 D155ATA04 3.5~4.5 ton(*) 153~163 13~18 3.5~4.5 ton(**) 130~140 5.0~7.0 ton 4~6.5 * 35DS/40DS/45DS-7, 35D/40D/45D-7(-#1000) ** 35D/40D/45D-7(#1001-, TIER II)

  • Page 174: Check Oil Level

    CHECK OIL LEVEL Embossed letter Stop the machine in a flat place and Inner cap check the oil level with the dipstick. Brake reservoir Normal Check the brake reservoir, and add brake 25-45 mm fluid, if necessary. The embossed letter (1-1.8 in) facing up.

  • Page 175: Travel System

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

  • Page 176: Steering System

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

  • Page 177: Adjustment Of Parking Brake Lever

    5. ADJUSTMENT OF PARKING BRAKE LEVER 1. RATCHET TYPE PARKING LEVER(1.5~1.8 TON ONLY) Put the lever in the brake released position. 1.5~1.8 ton HDF15/18-5 Tighten it with a adjust screw to give a force Stopper of 20kg to the lever operation. button Knob Adjust...

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