Hyundai 110DF-7 Manual
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Hyundai 110DF-7 Manual

Hyundai 110DF-7 Manual

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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
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
1. General locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
2. Data/safety plate and decal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2
3. Cab devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-4
4. Cluster - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-5
CONTENTS

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Summary of Contents for Hyundai 110DF-7

  • 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: 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. 16,17,18,19,20,21 "VIEW" (RADIATOR TOP) CABIN INSIDE RCV LEVER DASH BOARD COVER CABIN INSIDE-RH CABIN INSIDE-LH VIEW B VIEW A 160DF7OM101...
  • Page 9 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 10 RADIATOR FAN (Item 32) This warning label is positioned on the top side of cooling fan shroud. Warn of the danger or injury from spinning fan blades when the engine is running. Be sure that you keep your hands, fingers, arms and clothing away from a spinning fan.
  • Page 11 Tighten the banfo bolt at the supply line. Re-cranking. If the engine still would not start, please contact the nearest HYUNDAI or Cummins dealers. START WARNING (Item 24) This warning label is positioned on the middle side of dashboard cover.
  • Page 12 S S AFETY INSTRUCTION (Item 13) Truck for equipped with *OPSS. This warning label is positioned on the SAFETY INSTRUCTIONS SAFETY INSTRUCTIONS inside of cabin door if the truck is for This forklift equipped with an operator existence sensingsing equipped with *OPSS. system per ASME/ISO 3691 Power travel movement of the truck shall be possible only if the operator is in the normal operating position.
  • Page 13 OPERATOR SAFETY (Item 15) This warning label is positioned on the inside of LH cabin door. ※ Refer to page 3-3. 25L7A0OM09-1 ENGINE ROOM (Item 23) This warning label is positioned on the both side of engine hood. Don't wash the engine room. 25L7A0OM01 0-10...
  • Page 14 TILT CABIN WARNING (Item 27, 35) This warning label is positioned on the lift side of frame. 92FT-40720 92FT-40720 When tilting cab for service, the cab MUST BE FULLY EXTENDED UP or DOWN. To raise cab, depress switch down until fully When tilting cab for service, the cab When tilting cab for service, the cab MUST BE FULLY EXTENDED UP or DOWN.
  • Page 15 TURBO CHARGER COVER (Item 9) This warning label is positioned on the left side of frame. Don't touch on the exhaust pipe or it may cause severe burn. 21070FW02 0-12...
  • Page 16 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 17: 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 18: 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 19 Don't operate the truck outdoors in rainy day. ※ E xclude the truck equipped cabin. 160DF7OM07 Exhaust gas is dangerous. Do not operate the truck at the inhouse, if possible. Provide adequate ventilation when working in a closed space. 160DF7OM08...

  • Page 20: Seat Belts

    3. SEAT BELTS Always buckle up for the truck equipped with safety belt. 160D7OM09 Seat belts can reduce injuries. 160D7OM11...

  • Page 21: No Riders

    4. NO RIDERS The operator is the only one who should be on a truck. 160DF7OM12 Never transport personnel on the forks of a lift truck. 160DF7OM14...

  • Page 22: 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. 160DF7OM05 Watch for people in your work area even if your truck has warning lights or alarms.

  • Page 23: 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. 160DF7OM16...

  • Page 24: 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. 160DF7OM14 Always lower the load slowly. Raise and lower with mast vertical or tilted slightly back(Never forward).

  • Page 25: Pinch Points

    8. PINCH POINTS Keep hands, feet and legs out of the mast. D255OM61 Don't use the mast as a ladder. 160DF7OM62 Never try to repair the mast, carriage, chain, or attachment by yourself. Always get a trained mechanic. 160DF7OM63...

  • Page 26: 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. 160DF7OM18 When handling bulky loads that restrict your vision operate your truck in reverse to improve visibility.

  • Page 27: Grades, Ramps, Slopes And Inclines

    10. GRADES, RAMPS, SLOPES AND INCLINES Never turn on a grade, either loaded or unloaded. Unloaded-Forks downgrade 160DF7OM30 Loaded - Forks upgrade 160DF7OM33 1-11...

  • Page 28: 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 29 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 30: 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 31: Parking

    13. PARKING Never park on a grade. 160DF7OM41 Always come to a complete stop before leaving truck. Be sure travel control is in NEUTRAL. 160DF7OM42 Lower forks fully to floor and tilt forward. 160DF7OM44 Set parking brake. Position 1 : OFF(Release) Position 2 : ON(Lock) Turn key to OFF position.

  • Page 32: Refueling

    14. REFUELING Before adding oil, check around truck for oil leakage. 160DF7OM47 Keep away from fire when adding oil or during operation. 160DF7OM48 After adding oil, wipe off any oil spilled on truck. 160DF7OM49 1-16...

  • Page 33: Step

    15. STEP When getting on or off the truck, use the step provided. 160DF7OM50 Do not jump up or down from the truck. 160DF7OM52 1-17...

  • Page 34: 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. 160DF7OM18 Parking brake must be locked in the PARK POSITION before exiting from the vehicle. Parking brake must remain locked in the 1.

  • Page 35: Operating Hazards

    2. OPERATING HAZARDS 1. LOOSE LOADS Loose or unbalanced loads are dangerous. Observe these precautions. Never carry loose or uneven material. 160DF7OM53 Center wide loads. 160DF7OM55 Stack and band loose material. D35AOM41 Avoid sudden braking or starting When the truck is loaded, do not drive at maximum speed.

  • Page 36: 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 37: 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. 160DF7OM73 Watch overhead clearance: Moving into overhead structures can tip a truck over, or spill a load. 160DF7OM74 5.

  • Page 38: 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. 160DF7OM75 7. CHAIN SLACK Slack chains mean rail or carriage hang- Raise the forks before you move, or broken chains can result.

  • Page 39: 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 40: Lifting Loads

    10. LIFTING LOADS Never permit any persons to stand or pass under lifted load. 160DF7OM58 Never use wire rope to lift a load. 160DF7OM60 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 41 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 42: 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. 160DF7OM75A...

  • Page 43: Know Your Truck

    3. KNOW YOUR TRUCK 1. GENERAL LOCATIONS 110DEOM54 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 16 Front wheel Carriage 11 Work lamp-cabin rear 17 Rear combination lamp Forks 12 Operator's seat...

  • Page 44: 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. 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 45 OPERATOR SAFETY WARNING DECAL 250D7EOM59 Safety and warning decals are placed in conspicuous locations on the truck to remind you of essential procedures or to prevent you from making an error that could damage the truck or possibly cause personal injury. You should know, understand, and follow these instructions.

  • Page 46: Cab Devices

    3. CAB DEVICES The ergonomically designed console box and suspension type seat provide the operator with comfort. ELECTRONIC MONITOR SYSTEM The centralized electronic monitor system allows the status and conditions of the truck to be monitored at a glance. It is equipped with a safety warning system for early detection of truck malfunction. Front Rear Radio and USB player...

  • Page 47: 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 48 GAUGE Speed meter The speedmeter displays the speed of truck in mph and km/h. 7807A3CD03 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.

  • Page 49: Warning Lamps

    WARNING LAMPS Transmission oil temperature warning lamp Brake fail warning lamp T/M error warning lamp Engine coolant temp warning lamp Parking brake warning lamp Seat belt warning lamp OPSS warning lamp Engine oil pressure warning lamp Battery charging warning lamp Water in fuel warning lamp Air cleaner warning lamp...
  • Page 50 Immediately pull the truck to a convenient stop. Stop the engine. Investigate the cause. Consult a HYUNDAI dealer to investigate the cause. 160D7ECD19 Do not operate until the cause has been corrected.
  • Page 51 Water in fuel warning lamp This lamp lights up when the water separators full of water or malfunctioning. When this lamp lights up, stop the truck and spill water out of the separator. 160D7CD15 Seat belt warning lamp This lamp lights ON for the first five seconds after starting the truck.
  • Page 52 (13) OPSS warning lamp (option) 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. Transmission will automatically shift to neutral upon the exiting of the operator. The forward/reverse lever must be cycled through neutral with 160D7ECD14 the operator in the normal operating position to regain powered...

  • Page 53: Pilot Lamps

    PILOT LAMPS Head light pilot lamp Right turning pilot lamp Left turning pilot lamp Work lamp pilot lamp Fuel heater pilot lamp Preheater pilot lamp Inching pilot lamp 160D7ECD02-2 Direction pilot lamp This lamp flashes when the signal indicator lever is moved. 77073CD10 Work lamp pilot lamp (rear) This lamp lights ON when rear work lamp switch is pressed.
  • Page 54 Head light pilot lamp This lamp comes ON when the main light switch is operated to 2nd step. 160D7CD07 Preheater pilot lamp This lamp lights ON when start switch is turned clockwise to the ON position. Light will turn off after approximately 15~45 seconds, depending on engine coolant temperature, indicating that preheating is completed.
  • Page 55 CLUSTER BUTTON Each button has the following function. Buzzer stop button Next button MENU button 160D7ECD121E Buzzer stop button This button is used to stop the buzzer sound. If another alarm condition occurs after this button has been pressed, the alarm buzzer will re-sound. 160D7ECD22 Menu button To select engine error display mode, press this button.
  • Page 56 Menu and next buttons These buttons are used to select the model select mode. The initial model is selected at the factory, so don't change the different model. 80D9CD200/201 3-14...
  • Page 57 LCD has the functions to display start mode, standby mode, engine error display etc. Name and display Description Start mode - Displays initialization state with HYUNDAI logo and program version. Standby mode Displays on the idle state. Displays engine speed, odometer and hourmeter.

  • Page 58: Transmission Message Indicator

    5.TRANSMISSION MESSAGE INDICATOR 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 59 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 60 DISPLAY DURING AEB-MODE Symbol Meaning Remarks A E B - s t a r t e r i s p l u g g e d a t t h e diagnostic plug AEB-Starter-button is pressed K1..K3 Calibrating clutch K1...K3, KV or KR KV, KR resp.
  • Page 61 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 62: Switches

    6. SWITCHES Cover Parking brake switch Auto/Manual select switch Inching switch Main light switch Work lamp switch Hazard switch Cover(LH) Rear wiper/washer switch Aircon switch Seat heat switch Lock lever Inc/Dec switch Air compressor switch Fuel heater switch STOP DOWN Cover Cabin tilt switch DETAIL A...
  • Page 63 HAZARD SWITCH Use for parking, or loading truck. If the switch is left ON for a long time, the battery may be discharged. 160D7CD42 CLUTCH CUT-OFF SWITCH If this switch is pressed, inching operation is applied to inching pedal. Also, inching lamp on the cluster is illuminated. 160D7CD43 PARKING BRAKE SWITCH This switch is used to parking brake lock or release.
  • Page 64 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 first step position.

  • Page 65: Master Switch

    CENTER HORN 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. 160D7ECD28 CAB LAMP SWITCH This switch turns ON the cab room lamp. 73033CD24 MULTI FUNCTION SWITCH Front wiper and washer switch When the switch is in J position, the wiper moves intermittently.

  • Page 66: Airconditioner Switch

    FUEL HEATER SWITCH This switch is used to heat the fuel of pre-heater. 180D7ECD101 AIRCONDITIONER SWITCH This switch is used to aircon compressor ON or OFF. 250D7ECD102 AIR COMPRESSOR SWITCH This switch is used to operate air compressor. 110DECD61 3-24...

  • Page 67: 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 110DECD08 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 68 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. 160D7CD17 LEVER FOR SIDE SHIFT WITH FORK POSITIONER FORK POSITIONER (SYNCHRONIZER TYPE) OUTSTRECH THE FORKS Outstrech...

  • Page 69: Gear Selector Lever

    RH FORK MOVEMENT Outward - Push the lever forward to move outward for the RH fork. - Pull the lever backward to move inward for the RH fork. Inward 160D7CD22 GEAR SELECTOR LEVER This lever is used for gear selection, forward 3 stages and reverse 3 Acceleration stages.

  • Page 70: Accelerator Pedal

    ACCELERATOR PEDAL This pedal controls the engine speed. The engine speed will increase in proportion to the degree of force applied to this pedal. Unless this pedal is pressed, the truck will run at low idling. 160D7ECD32 INCHING PEDAL Inching pedal is used for fine control of forward and reverse movement when lifting up or putting down loads.

  • Page 71: 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 110DECD90 3-29...

  • Page 72: Fan Speed Control Switch

    FAN SPEED CONTROL SWITCH It is possible to control the fan speed to four steps. 160D7ECD50 AIR POSITION CONTROL SWITCH This switch regulates the air position. Front Front & rear Rear Front & defrost Defrost 160D7ECD51 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 73: Others

    9. OTHERS Front Engine Radio and USB player control unit(ECU) Rear Transmission control unit(TCU) Monitor(opt) Cigar lighter Handsfree(opt) Fuse box Seat 110DECD09 3-31...

  • Page 74: 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. T h e s e a t c a n b e m o v e d f o r w a r d a n d backward over 200 mm (8 in) in 10 steps.
  • Page 75 FUSE BOX Fuse box #1 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 76: 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 110D7ECD100E Power button To turn the power off or on.
  • Page 77 Name Description Starting animation Main screen Load/R.W angle Load/R.W angle Camera selection To enter camera screen, press the button. To return to menu selection screen, press button. If you turn "Reverse Mode" on, camera view be shown at reverse or neutral gear. - Reverse : camera 1 - Neutral : camera 2 3-54...
  • Page 78 Name Description Display set up screen LCD brightness To adjust to display brightness, press to decrease or increase. Language selection Set a Korean or English. Unit setting Set a unit load indicator. 3-55...
  • Page 79 Name Description Mode set up screen 1)Option Load/ R.W angle Display the conditions for load indicator. Applied to the main screen, check the page 3-53. When you choose 'Load Indicator ON', you can pick O N / O F F o f o v e r w e i g h t buzzer.
  • Page 80 Name Description Mode set up screen 2)Rear wheel calibration The user revises a forklift truck steering angle. Display set to approve a condition. Right set rear wheel calibration. To the left as possible to steer wheel (Steer wheel Left) Press the Center set rear wheel calibration.
  • Page 81 Name Description Mode set up screen 3)Load indicator setting MAST Select Equipment model selection varies depending on the mast. Calibration Correct a fork-lift load indicator After input passwords, you must input *. D e f i n e p a s s w o r d i s : "00008282"...
  • Page 82 Name Description Mode set up screen Weight correction Input a password Loaded enter the weight. (Input ton) In the loaded from the around waiting 5 seconds after lift 30 cm Weight correction ON 3-59...
  • Page 83 Name Description Mode set up screen 4)Maintenance Change the replacement cycle of expandable supplies. Using button for changing the replacement cycle. 3-60...
  • Page 84 Name Description Mode set up screen Service Contact Check and change of contact information for customer service. 3-61...
  • Page 85 Name Description Mode set up screen RMCU communication When successfully opened RMCU communication, except for the RMCU communication. 3-62...
  • Page 86 Name Description Mode set up screen 7)Camera select Gear linkage mode If you turn “Reverse mode” on, camera view be shown at reverse or neutral gear on main. - Reverse : camera 1 - Neutral : camera 2 Operation CAM set Set the number of operation camera.
  • Page 87 Name Description Ending animation 3-64...

  • Page 88: 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 89: 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 90: 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 91: 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 92: 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 93: 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 94: 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 95: 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 96: 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 97: Check Hydraulic Oil Level

    Gauge ℓ(U.S.gal) V - mast TF - mast Model Level gauge Lower limit 111(29) V300 ~ V700 TF440 ~ TF700 110DF-7 160D7MA14 130DF-7 123(32) Upper limit TF440 ~ TF700 Lower limit 124.3(32.8) V300 ~ V600 TF395 ~ TF450 160DF-7 135.6(35.8)
  • Page 98 CHECK PEDALS Check for any catching or abnormal heaviness when depressing the pedals. Inching pedal Stroke ① Free play : Max 1° ② Interlock stroke with brake pedal : 7° Brake pedal ① Free play : Max 1° 110DETA04...

  • Page 99: 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 100: 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. · The parking brake is applied. Parking switch ON ·...

  • Page 101: 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 102: Starting And Stopping The Engine

    7 7 . STARTING AND STOPPING THE ENGINE CHECK INDICATOR LIGHTS Gear selector lever Check if parking brake switch is ON. Parking brake switch Check if gear selector lever is in neutral position. Turn the key to the ON position, and check following.
  • Page 103 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 104 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 105: 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 106: Warming-Up Operation

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

  • Page 107: 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 108 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 109: 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. 160DF7OP10 Traveling operation When warm-up operation is completed after the Gear selector lever engine is started, move the truck according to Parking brake switch...
  • Page 110 ※ 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 111 Stopping the truck ① Press the brake pedal to stop the truck. Gear selector lever ② Put the gear selector lever in the neutral Parking brake switch position. ③ Press the parking brake switch. 110DEOP14 ④ Lower the forks to the ground. Low idling for 5 minutes 160DF7OP07...
  • Page 112 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 113: 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 114 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 115: 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 116 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 117 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 118 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 119 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 120 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 121: 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 122: 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 123: 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 124: Loading And Unloading By Crane

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

  • Page 125: 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 126 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 127: 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 128 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 129: Planned Maintence And Lubrication

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

  • Page 130: 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 131 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 132 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 133: 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 134: 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 135 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.

  • Page 136: Planned Maintenance Intervals

    4. PLANNED MAINTENANCE INTERVALS MAJOR COMPONENTS LOCATION 15 12 14 9 10 11 160DF7OM21 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...
  • Page 137 MAINTENANCE CHECK LIST EVERY 10 HOURS SERVICE Check items Service Remarks Visual inspection ·Truck for obvious damage and leaks. 7-14 Check, Repair or Replace ·Warning plates and decals. 7-14 Check, Replace ·Condition of tires and wheels. Air pressure. 7-16 Check, Refill or Replace ·Lift chain and fastener.
  • Page 138 INITIAL 100 HOURS SERVICE Check items Service Remarks Differential gear oil Change 7-40 Transmission oil and filter Replace 7-39 Brake cooling oil Change 7-41 EVERY 250 HOURS SERVICE Check items Service Remarks 7-40 Differential gear oil Check, Refill 7-33 Pilot line filter element Replace 7-33 Brake line filter(strainer)
  • Page 139 Replace 7-32 Conventional hydraulic oil EVERY 5000 HOURS SERVICE Check items Service Remarks Replace 7-32 Hydraulic oil(* Hyundai genuine long life hydraulic oil WHEN REQUIRED Check items Service Remarks Fuel system 7-26 ·Fuel tank Drain or Clean 7-28 ·Water separator...

  • Page 140: 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 141: Maintenance Chart

    Check, Clean Hydraulic oil Change 5000 Hours Hydraulic oil Change Conventional hydraulic oil 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 142: 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 143 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 between both fork tips refer to below table. allowed Fork length Height...

  • Page 144: 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 145 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. ※...
  • Page 146 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 110DEMI64 The angle of fully tilted cabin is 65 。 。 and the safety lock function operates within the tilting angle of 20 。...

  • Page 147: Service Instruction

    7. SERVICE INSTRUCTION CHECK ENGINE OIL LEVEL Check the oil level with the machine on a flat 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. If oil level is LOW, add oil and then check again.
  • Page 148 Apply a light film of lubricating oil to the gasket Oil filter cap sealing surface before installing the oil filter cap. O-ring Element Oil cooler 300H6MA14 Replace the element of the engine oil filter and Close new O-ring (2EA) and install the oil cap into oil cooler.
  • Page 149 CHECK COOLANT LEVEL Check the coolant level at reservoir tank. Add the mixture of antifreeze and water after if coolant is not sufficient. Normal The coolant level should indicate the middle position. Replace gasket of radiator cap when it is damaged.
  • Page 150 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 151 ※ 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. ·...
  • Page 152 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. ·...

  • Page 153: 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 154 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 155: 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 156 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. ※...
  • Page 157 ④ Lubricate new bowl seal with clean fuel or motor oil and place in bowl gland. Filter head ⑤ Attach bowl to new element firmly by hand. Fuel warmer ⑥ Lubricate new element seal and place in element top gland. Close ⑦...

  • Page 158: Hydraulic Oil Check

    ⑧ Do hand-priming the lift pump repeatedly until Plug air bubbles comes out the air bleed hole completely. ⑨ Tighten the air bleed plug. Lift pump ※ Operate the engine at low idle for 2~3 minutes and check for leaks. 300H6MA09 LEAKAGE OF FUEL F F IRE!!!

  • Page 159: Filling Hydraulic Oil

    FILLING HYDRAULIC OIL Stop the engine to the position of level check. Air breather Check air breather filter and replace it if necessary. Loosen cap and fill the oil to the specified level. Start engine after filling and operate the work equipment several times.
  • Page 160 CLEANING AND REPLACING RETURN FILTER Clean and replace the return filter in the following manner. Remove the flange by loosening the mounting Flange bolt. Remove return filter from the tank. Replace the return filter element with new one. Return filter Install the cover on the tank.
  • Page 161 CLEANING BRAKE LINE FILTER Cut-off Remove the strainer from the filter body. valve Wash the strainer with cleaning oil. Install and tighten using specified torque. ·Tightening torque : 6~8kgf·m(43.4~57.9lbf·ft) 160D7EMI24 LUBRICATE RCV LEVER Bellows Remove bellows and grease the joint(A) and the sliding parts(B).

  • Page 162: Tire Pressure

    TIRE PRESSURE Inappropriate tire pressure is a primary cause for tire damage. Insufficient tire pressure will damage internal carcass of tire. Repeated excessive bending will damage or break the carcass. Excessive pressure will also cause premature damage of tire. Recommended tire pressure(When tire is cooled) Model Pressure...

  • Page 163: 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.
  • Page 164 ② Loosen slightly all wheel mounting. ·Tools : Socket 32mm Torque wrench Extension bar ③ Lift the machine with a jack. ④ Loosen all wheel mounting nuts and replace the tire. Torque wrench 160D7MI37 Direction of tire to be installed ①...
  • Page 165 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 166 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 160D7MI43 Apply a light coat of oil to the gasket of a new transmission oil filter cartridge.
  • Page 167 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 168 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 169 Supply oil into the differential gear and the Differential gear planetary gear. ·Oil amount : 19ℓ(5.0U.S. gal) Supply oil until it overflows from the oil filler, then install the plug. s the machine is hot after operation, wait until the temperature has dropped. Fill &...
  • Page 170 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 171 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 ※...

  • Page 172: 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 173: 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 174: 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 terminals after washing.

  • Page 175: 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 176: Transmission Oil

    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 177: Differential Case

    DIFFERENTIAL CASE Differential oil Park the truck in a level place. Set the mast vertical, and raise the forks approx. 1m. Put blocks under the fork carriage. Then stop the engine and apply the parking Air breather brake. Oil level check Remove level plug, and check that oil is filled up to hole.

  • Page 178: 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 160DF7OM28 Strainer Cleaning OSHA-approved eye protection rated for 200kPa(30psi) is required for air cleaning operation. ①...

  • Page 179: 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. ②...
  • Page 180 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 181: Fuses Replacement

    FUSES REPLACEMENT Fuse box #1 Capacity Color Related electrical component START KEY ① ① Start key 시동키 FUSE ② TCU(B HOLDER TCU(B+) ③ Turn lamp ② T/M 컨트롤러 ④ OPSS(B TURN LAMP HORN(B+) ⑤ Blue ECU(B ⑫ ③ 방향지시등 경음기 ⑥...

  • Page 182: Functional Tests

    LAMP BULBS REPLACEMENT Lamp Spec(24V) Head lamp(up) Head lamp(down) Turn signal lamp Clearance lamp Stop lamp Backup lamp License lamp (option) 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 183 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 184 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 185 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 186 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 187: 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 188 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 189 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 190: 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 191: 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 192: 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 Hydraulic oil ISO VG32/VG46/VG68, Hyundai genuine long life hydraulic oil Grease Lithium base grease NLGI No.2 Fuel ASTM D975-No.2 Coolant Mixture of 50% ethylene glycol base antifreeze and 50% water ㆍSAE : Society of Automotive Engineers...

  • Page 193: Fuel And Lubricants

    14. FUEL AND LUBRICANTS 。 C (。 F) Capacityℓ(U.S.gal) Ambient temperature Service Kind of 110DF-7 point fluid 160DF-7 130DF-7 (-4) (14) (32) (50) (68) (86) (104) SAE 30 SAE 10W Engine oil 24.5 24.5 Engine oil (6.5) (6.5) SAE 10W-30...

  • Page 194: Specification

    8. SPECIFICATIONS 1. SPECIFICATION TABLE C' C 160DF7SP011 Model Unit 110DF-7 130DF-7 160DF-7 Capacity kg(lb) 11,000(25000) 13,000(29000) 16,000(36000) Load center ← ← mm(in) 600(24") Weight(Unloaded) kg(lb) 16454(36270) 17592(38780) 19765(43570) ← ← Lifting height mm(ft-in) 3000(9' 10") ← ← Free lift...

  • Page 195: Main Control Valve

    2 2 . SPECIFICATION FOR MAJOR COMPONENTS 110/130DF-7 ENGINE Item Specification Unit Model HMC D6GA Type 4 cycle turbocharged, Intercooler 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 Cylinder bore X stroke mm(in) 103×118mm(4.06"×4.65")

  • Page 196: Steering Unit

    TEERING 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 2.066 : 1 Type Full auto, power shift...
  • Page 197 160DF-7 ENGINE Item Specification Unit Model HMC D6GA 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 103×118mm(4.06"×4.65") cc(cu in) Piston displacement 5899(360)
  • Page 198 TEERING UNIT Item Unit Specification Type Load sensing/Non load reaction/Dynamic signal Capacity cc/rev Rated flow 45.4 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 2.066 : 1 Type Full auto, Power shift Gear shift(FR/RR)

  • Page 199: Tightening Torque

    3. TIGHTENING TORQUE 110/130/160DF-7 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 92 ± 21.7 Hydraulic pump mounting bolt M12 × 1.75 9.0 ±...

  • Page 200: 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 201: 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. ·Improper belt tension. ·Adjust belt tension. Lamps flicker during engine operation. Charge lamp does not light du ·Charge lamp defective.
  • Page 202 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 203 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 204 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 205 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 206: 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 207: 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 208: 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 209: 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 210: 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 211 Move fan backwards and forwards by hand to check for looseness. Tighten mounting bolt with a spanner. Crack 160D7TA11 10-3...

  • Page 212: 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 213 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 214: 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 215: 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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