Hyundai 110D-7A Manual
  1. Manuals
  2. Brands
  3. Hyundai Manuals
  4. Forklifts
  5. 110D-7A
  6. Manual
Hyundai 110D-7A Manual

Hyundai 110D-7A Manual

Hide thumbs Also See for 110D-7A:
Table of Contents

Advertisement

Quick Links

Download this manual
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 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
CONTENTS
CONTENTS

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 110D-7A and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Hyundai 110D-7A

Summary of Contents for Hyundai 110D-7A

  • Page 1: Table Of Contents

    CONTENTS CONTENTS 1. SAFETY HINTS 1. SAFETY HINTS 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.
  • Page 2 3. KNOW YOUR TRUCK 3. KNOW YOUR TRUCK 1. General locations ----------------------------------------------------------------------------------------------------------- 3-1 2. Data/safety plate and decal ------------------------------------------------------------------------------------------ 3-2 3. Cab devices ------------------------------------------------------------------------------------------------------------------- 3-4 4. Cluster ---------------------------------------------------------------------------------------------------------------------------- 3-5 5. Transmission message indicator --------------------------------------------------------------------------------- 3-16 6. Switches ------------------------------------------------------------------------------------------------------------------------- 3-20 7. Control device ---------------------------------------------------------------------------------------------------------------- 3-26 8.
  • Page 3 7. PLANNED MAINTENANCE AND LUBRICATION 7. PLANNED MAINTENANCE AND LUBRICATION 1. Introduction -------------------------------------------------------------------------------------------------------------------- 7-1 2. Safe maintenance practices ---------------------------------------------------------------------------------------- 7-2 3. Instructions before maintenance --------------------------------------------------------------------------------- 7-5 4. Planned maintenance intervals ----------------------------------------------------------------------------------- 7-8 5. Maintenance chart -------------------------------------------------------------------------------------------------------- 7-12 6. How to perform planned maintenance ----------------------------------------------------------------------- 7-14 7.
  • 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 The descriptions and specifications included in this manual were in effect at the time of printing. HYUNDAI reserves the right to make improvements and changes in specifications or design, 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 EC REGULATION APPROVED EC REGULATION APPROVED · Noise level (2000/14/EC and EN 12053) are as followings. Model (EU only) 110D/130D/160D-7A 78 dB 108 dB · The value of vibrations transmitted by the operator's seat are lower than standard value of (2002/44/...

  • Page 9: Safety Labels

    SAFETY LABELS SAFETY LABELS 1. LOCATION 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 31 24 "VIEW" (RADIATOR TOP) CABIN INSIDE RCV LEVER DASH BOARD COVER VIEW -A- VIEW -B- CABIN INSIDE-RH...
  • Page 10 2. DESCRIPTION 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 FORK (ltem 2) This warning label is positioned on the left side of the mast.

  • Page 11: Radiator Fan

    RADIATOR FAN RADIATOR FAN (Item 32) This warning label is positioned on the top side of cooling fan shroud. War n of the danger or injur y from War n of the danger or injur y from spinning fan blades when the engine is spinning fan blades when the engine is running.

  • Page 12: Start Procedure

    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 START WARNING (Item 24) This warning label is positioned on the middle side of dashboard cover.
  • Page 13 SAFETY INSTRUCTION SAFETY 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 14: Operator Safety

    OPERATOR SAFETY OPERATOR SAFETY (Item 15) This warning label is positioned on the inside of LH cabin door. ※ Refer to page 3-3. Refer to page 3-3. 25L7A0OM09-1 ENGINE ROOM ENGINE ROOM (Item 23) This warning label is positioned on the both ENGINE WASH side of engine hood.
  • Page 15 TILT CABIN WARNING 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 16 TURBO CHARGER COVER 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 Don't touch on the exhaust pipe or it may cause severe burn. cause severe burn.

  • Page 17: Engine Serial Number

    GUIDE GUIDE 1. DIRECTION 1. DIRECTION The directions of this truck indicate forward, Front backward, right and left when truck is in the travelling direction. Left Right Rear 160D7ASM01 2. SERIAL NUMBER 2. SERIAL NUMBER Inform following when you order parts or the truck is out of order. 1) 1) TRUCK SERIAL NUMBER TRUCK SERIAL NUMBER...

  • Page 18: Safety Hints

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

  • Page 19: Do's And Don'ts

    2. 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. 160D7OM04 Don't smoke in NO SMOKING areas or when refueling. D35AOM06...
  • Page 20 Don't operate the truck outdoors in rainy day. ※Exclude the truck equipped cabin. Exclude the truck equipped cabin. 160D7AOM07 Exhaust gas is dangerous. Do not operate the truck at the inhouse, if possible. Provide adequate ventilation when working in a closed space. 160D7AOM08...

  • Page 21: Seat Belts

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

  • Page 22: No Riders

    4. NO RIDERS 4. NO RIDERS The operator is the only one who should be on a truck. 160D7AOM12 Never transport personnel on the forks of a lift truck. 160D7AOM14...

  • Page 23: Pedestrians

    5. PEDESTRIANS 5. PEDESTRIANS Watch where you are going. Look in the direction of travel. Pedestrians may use the same roadway you do. Sound your horn at all intersections or blind spots. 160D7AOM05 Watch for people in your work area even if your truck has warning lights or alarms.

  • Page 24: Operator Protection

    6. 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 Do not operate truck without cabin or overhead guard, unless condition prevent overhead guard, unless condition prevent use of it.

  • Page 25: Fork Safety

    7. 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. 160D7AOM14 Always lower the load slowly. Raise and lower with mast vertical or tilted slightly back(Never forward).

  • Page 26: Pinch Points

    8. PINCH POINTS 8. PINCH POINTS Keep hands, feet and legs out of the Keep hands, feet and legs out of the mast. mast. D255OM61 Don't use the mast as a ladder. Don't use the mast as a ladder. 160D7AOM62 Never try to repair the mast, carriage, Never try to repair the mast, carriage, chain, or attachment by yourself.

  • Page 27: Travel

    9. TRAVEL 9. TRAVEL Travel with the load near the floor/ground, with mast tilted back to cradle the load whenever possible. Never lift or lower the load when the Never lift or lower the load when the truck is in motion. truck is in motion.

  • Page 28: Grades, Ramps, Slopes And Inclines

    10. GRADES, RAMPS, SLOPES AND INCLINES 10. GRADES, RAMPS, SLOPES AND INCLINES Never turn on a grade, either loaded or unloaded. Never turn on a grade, either loaded or unloaded. Unloaded-Forks downgrade 160D7AOM30 Loaded - Forks upgrade 160D7AOM33 1-11...

  • Page 29: Tip Over

    11. TIP OVER 11. TIP OVER 1) 1) LATERAL TIP OVER LATERAL TIP OVER L a t e r a l t i p o ve r c a n o c c u r w i t h a combination of speed and sharpness of turn.
  • Page 30 3) 3) WHAT TO DO IN CASE OF A TIP OVER WHAT TO DO IN CASE OF A TIP OVER If your truck starts to tip over, Do not If your truck starts to tip over, Do not jump. jump. Brace yourself as illustrated right.

  • Page 31: Surface And Capacity

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

  • Page 32: Parking

    13. PARKING 13. PARKING Never park on a grade. 160D7AOM41 Always come to a complete stop before leaving truck. Be sure travel control is in NEUTRAL. 160D7AOM42 Lower forks fully to floor and tilt forward. 160D7AOM44 Set parking brake. Position 1 : OFF(Release) Position 2 : ON(Lock) Turn key to OFF position.

  • Page 33: Refueling

    14. REFUELING 14. REFUELING Before adding oil, check around truck for oil leakage. 160D7AOM47 Keep away from fire when adding oil or during operation. 160D7AOM48 After adding oil, wipe off any oil spilled on truck. 160D7AOM49 1-16...

  • Page 34: Step

    15. STEP 15. STEP When getting on or off the truck, use the step provided. 160D7AOM50 Do not jump up or down from the truck. 160D7AOM52 1-17...

  • Page 35: Operator's Safety Rules

    16. OPERATOR'S SAFETY RULES 16. OPERATOR'S SAFETY RULES All operational functions require that the operator be seated in the operator's seat. A l way s bu ck l e u p i f a s e a t b e l t i s A l way s bu ck l e u p i f a s e a t b e l t i s provided.

  • Page 36: Operating Hazards

    2. OPERATING HAZARDS 2. OPERATING HAZARDS 1. LOOSE LOADS 1. LOOSE LOADS L o o s e o r u n b a l a n c e d l o a d s a r e L o o s e o r u n b a l a n c e d l o a d s a r e dangerous.

  • Page 37: Long And Wide Loads

    2. LONG AND WIDE LOADS 2. LONG AND WIDE LOADS With long or wide loads, you need more With long or wide loads, you need more room. So slow down and watch your room. So slow down and watch your clearance.

  • Page 38: Low Overhead Clearance

    4. LOW OVERHEAD CLEARANCE 4. LOW OVERHEAD CLEARANCE Know the height of your truck, with and Know the height of your truck, with and without a load. Check your clearances. without a load. Check your clearances. Keep the load low and tilted back. Keep the load low and tilted back.

  • Page 39: Right Angle Stacking

    6. RIGHT ANGLE STACKING 6. RIGHT ANGLE STACKING When right angle stacking or moving with When right angle stacking or moving with a raised load to clear low objects, avoid a raised load to clear low objects, avoid sharp turns and move slowly. sharp turns and move slowly.

  • Page 40: Pallets And Skids

    8. PALLETS AND SKIDS 8. PALLETS AND SKIDS Do not move or store materials on Do not move or store materials on damaged pallets or skids. Items can fall damaged pallets or skids. Items can fall through them causing severe injury or through them causing severe injury or death.

  • Page 41: Lifting Loads

    10. LIFTING LOADS 10. LIFTING LOADS Never permit any persons to stand or pass under lifted load. 160D7AOM58 Never use wire rope to lift a load. 160D7AOM60 11. SIDE SHIFT 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 42 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.

  • Page 43: Fork Positioner

    12. 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 Never move the levers to operate the pork positioner suddenly and quickly. pork positioner suddenly and quickly.

  • Page 44: Know Your Truck

    3. KNOW YOUR TRUCK 1. GENERAL LOCATIONS 160D7AOM54 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 45: 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 46 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 47: 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 48: 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 49 Fuel gauge This gauge indicates the amount of fuel in the fuel tank. Fill the fuel when the indicator moves E point, refuel as soon as possible to avoid running out of fuel. If the gauge indicates below E point even though the truck is on the normal condition, check the electric device as that can be caused by the poor connection of electricity or sensor.
  • Page 50 Direction pilot lamp This lamp flashes when the signal indicator lever is moved. 77073CD10 Work lamp pilot lamp (front / rear) This lamp lights ON when cabin work lamp switch is pressed. 77073CD11 Head light pilot lamp This lamp comes ON when the main light switch is operated to 2nd step.
  • Page 51 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 52 (12) Air cleaner warning lamp This lamp operates by the vacuum caused inside when the filter of air cleaner is clogged. Check the filter and clean or replace it when the lamp is ON. 77073CD20 (13) Battery charging warning lamp This lamp is ON after key switch is turned ON.
  • Page 53 (17) Engine coolant temperature warning lamp This lamp is turned ON when the temperature of cooling water is over the normal temperature (104˚C, 219˚F). Check the cooling system when the lamp is ON. 77073CD17 (18) Transmission oil temperature warning lamp This lamp informs the operator that transmission oil is above the specified temperature.
  • Page 54 CLUSTER BUTTON Each button has the following function. Buzzer stop button Next button MENU button 160D7ECD121E Buzzer stop button This swich is used to stop the buzzer sound. Stop the buzzer when the switch is pressed. 160D7ECD22 Menu and next button This swiches are used to choose the model or display the engine error on the LCD.
  • Page 55 LCD has the functions to display start mode, standby mode, cruise function, model select and engine error. Display Name Description Start mode Display initialization state with HYUNDAI logo and program version. Standby mode Displays on the idle state. Displays rpm, odometer and hourmeter Odometer is on, is activated.
  • Page 56 Display Name Description On model select mode, displays like this image. Model select Refer to the page 3-11. Engine error In case of below 4 engine errors displays like this image. display Refer to the page 3-11. In case of over 4 engine errors displays like this image.

  • Page 57: 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 58 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 59 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 60 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 61: Switches

    6. SWITCHES Cruise set-resume switch Cruise switch Cover Parking brake switch Auto/Manual select switch Clutch cut-off 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 Engine mode switch Fuel heater switch STOP DOWN...
  • Page 62 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 63 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 64: 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 CRUISE SWITCH When this switch is turned ON, the cruise ready mode is selected and cruise active is ready for activation.
  • Page 65 ENGINE MODE SWITCH This switch offers two selectable operating mode. POWER The operator can adjust the machine's performance with this STANDARD selection switch. Function STANDARD MODE : This mode provides maximum fuel efficiency for general loading. 160D7ECD60 POWER MODE : This mode provides maximum power output for heavy loading or hill climb.

  • Page 66: Master Switch

    MASTER SWITCH This switch is used to shut off the entire electrical system. When the machine is not operated for a long time, turn OFF the master switch for the safety purpose. I : The battery remains connected to the electrical system. O : The battery is disconnected to the electrical system.

  • 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 3-28...

  • 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 3-30...

  • 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. The seat can be moved forward and backw- ard 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. To switch the monitor on or off, press and hold the power button for two second.
  • Page 77 Name Description The password must be 5~10 ESL (Engine Starting Limit) screen digits long. After input password, you must input Default password : '0000000000'(digit '0', 10 times) Camera selection To enter camera screen, press button. To return to menu selection screen, press button.
  • Page 78 Name Description Changing password The password must be 5~10 digits long. After input password, you must input 3-54...
  • Page 79 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 80 Name Description Display set up screen Select on option Forklift change the main screen Rear wheel calibration The user revises a forklift truck streeing angle. Right set rear wheel calibration To the left as possible to steer wheel (steer wheel LEFT) Center set rear wheel calibration To the center as possible to steer wheel (steer wheel...
  • Page 81 Name Description Display set up screen Load indicator setting MAST Select Equipment model selection varies depending on the mast 110/130D-7A V-MAST TS-MAST 160D-7A V-MAST TS-MAST 3-57...
  • Page 82 Name Description Load indicator setting Display set up screen Calibration Correct a fork-lift load indicator After input passwords, you must input *. Define password is : "00008282" Tare In the unloaded from the g r o u n d w a i t i n g 8 seconds after lift 30 cm Tare ON Weight correction...

  • Page 83: 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 Do not operate a truck if it is in need of repair.

  • Page 84: Functional Checks

    2) 2) FUNCTIONAL CHECKS FUNCTIONAL CHECKS Check the operation of the truck as follows. ※ Before performing these checks, familiarize yourself with the starting, operating, and Before performing these checks, familiarize yourself with the starting, operating, and shutdown procedures in Section 5 of this manual. Also, know the safety rules given in shutdown procedures in Section 5 of this manual.

  • Page 85: Suggestion For New Truck

    2. 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...

  • Page 86: Fuel Safety Practices

    3. FUEL SAFETY PRACTICES 3. FUEL SAFETY PRACTICES REFUELING DIESEL TRUCKS 100D7OM106 Stop the engine when refueling. Stop the engine when refueling. All lights and flames shall be kept at a All lights and flames shall be kept at a safe distance while refueling.

  • Page 87: Starting And Operating Procedures

    5. STARTING AND OPERATING PROCEDURES 5. STARTING AND OPERATING PROCEDURES 1. BEFORE OPERATING THE TRUCK 1. BEFORE OPERATING THE TRUCK Be sure that you have read and understand the information in this Operator's Manual and are trained and authorized before operating the lift truck. A lift truck can be dangerous if not used properly.

  • Page 88: Check Before Operation

    2. CHECK BEFORE OPERATION 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 89: Check Before Starting Engine

    CHECK FOR WATER OR OIL LEAKAGE 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.

  • Page 90: Check Coolant Level

    3) 3) 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 In antifreeze is being used, pay careful attention to the ratio of antifreeze and water when adding coolant.

  • Page 91: Check Battery

    5) 5) CHECK FAN BELT TENSION 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 92: Check Hydraulic Oil Level

    Model Gauge V - mast TF - mast Level gauge Lower limit 111 (29) V300 ~ V700 TF440 ~ TF700 110D-7A 160D7MA14 130D-7A Upper limit 123 (32) TF440 ~ TF700 Lower limit 124.3 (32.8) V300 ~ V600 TF395 ~ TF450...
  • Page 93 CHECK PEDALS CHECK PEDALS Check for any catching or abnormal heaviness when depressing the pedals. (1) (1) Inching pedal Inching pedal Stroke ① Free play : Max 1° ② Interlock stroke with brake pedal : 7° (2) (2) Brake pedal Brake pedal ①...

  • Page 94: Seat Adjustment

    4. SEAT ADJUSTMENT 4. SEAT ADJUSTMENT 1) 1) SEAT ADJUSTMENT 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. (1) (1) Forward / Backward adjustment Forward / Backward adjustment ①...

  • Page 95: Starting From A Safe Condition

    5. 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. ·...

  • Page 96: General Starting And Operating Tips

    6. 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.

  • Page 97: Starting And Stopping The Engine

    7. STARTING AND STOPPING THE ENGINE 7. STARTING AND STOPPING THE ENGINE 1) 1) CHECK INDICATOR LIGHTS 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 98 3) 3) STARTING ENGINE IN A COLD WEATHER STARTING ENGINE IN A COLD WEATHER ※ Sound hor n to war n surroundings after Sound hor n to war n surroundings after checking if there are obstacles in the area. checking if there are obstacles in the area. ※...
  • Page 99 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 100: 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 TRANSMISSION COLD STARTING At an oil temperature in the shifting circuit <...

  • Page 101: Warming-Up Operation

    8. WARMING-UP OPERATION 8. WARMING-UP OPERATION ※ The most suitable temperature for the hydraulic Gear selector lever oil is about 50˚C (112˚F ). It can cause serious trouble in the hydraulic Parking brake switch s y s t e m by s u d d e n o p e ra t i o n w h e n t h e hydraulic oil temperature is below 25˚C (77˚F ).

  • Page 102: Levers And Pedals

    9. LEVERS AND PEDALS 9. LEVERS AND PEDALS 1) 1) POSITIONING FORKS AND MAST 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 103 2) 2) SELECTING DIRECTION OF TRAVEL 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 3) 3) USING THE ACCELERATOR PEDAL USING THE ACCELERATOR PEDAL With the parking brake released and the direction control in FORWARD or REVERSE, put your foot on the accelerator...

  • Page 104: Traveling Of The Truck

    10. TRAVELING OF THE TRUCK 10. TRAVELING OF THE TRUCK 1) 1) BASIC OPERATION BASIC OPERATION Tilt back fully (1) (1) Traveling posture Traveling posture Lift the forks so that the forks are placed 15~ 20 cm (6~8 in) above the ground and tilt back the mast fully.
  • Page 105 ※ When traveling at high speed, do not When traveling at high speed, do not abruptly decelerate by using the trans- abruptly decelerate by using the trans- mission lever, to slow down instead press the mission lever, to slow down instead press the brake pedal.
  • Page 106 Stopping the truck Stopping the truck (6) (6) 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...
  • Page 107 (7) (7) Stopping engine Stopping engine ※ If the engine is abruptly stopped before it has If the engine is abruptly stopped before it has Gear selector lever c o o l e d d o w n , i t s s e r v i c e l i fe m ay b e c o o l e d d o w n , i t s s e r v i c e l i fe m ay b e Parking brake switch shortened.

  • Page 108: Operating Safely

    11. 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... WATCH WHERE YOU ARE GOING. DON’T GO IF YOU CAN’T SEE... 1) 1) Before driving, check all around to be sure that your intended path of travel is clear of obstructions and pedestrians.
  • Page 109 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. 5) 5) GRADES, RAMPS, AND INCLINES...

  • Page 110: Load Handling

    12. LOAD HANDLING 12. LOAD HANDLING 1) 1) GENERAL GENERAL Handle only loads that are within the truck rated capacity as shown on the nameplate. This rating specifies the maximum load that should be lifted. However, other factors such as special load 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 111 2) 2) ADJUSTING THE LOAD FORKS 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.
  • Page 112 4) 4) TRAVELING WITH LOAD TRAVELING WITH LOAD Travel with load or carriage as low as possible and tilted back. Never travel with the load or 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.
  • Page 113 5) 5) PICKING UP AND MOVING LOADS PICKING UP AND MOVING LOADS When picking up a load from the ground, approach the load slowly and carefully align the truck square with the load. The forks should be adjusted to fit the load or pallet being handle and spread as wide as possible to provide good stability and balance.
  • Page 114 7) 7) STACKING STACKING To put a load on a stack To put a load on a stack (1) (1) 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...
  • Page 115 (2) (2) To move a load from a stack To move a load from a stack Approach the stack carefully, truck lined up squarely with the load. With mast vertical, raise the forks to the correct height for freely engaging the load pallet. Adjust fork angle as necessary to fit squarely under the load.

  • Page 116: Shut Down Procedure

    13. SHUT DOWN PROCEDURE 13. SHUT DOWN PROCEDURE ※ Always leave your lift truck in a safe condition. Always leave your lift truck in a safe condition. 1) 1) WHEN YOU LEAVE YOUR TRUCK, OR PARK IT, FOLLOW THESE SAFELY RULES WHEN YOU LEAVE YOUR TRUCK, OR PARK IT, FOLLOW THESE SAFELY RULES Park in a safe area away from normal traffic.

  • Page 117: 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 118: Transport

    PRECAUTIONS FOR LOADING AND UNLOADING 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 119: Loading And Unloading By Crane

    16. 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 To lift bracket with the machine as it should avoid touching with the truck body.

  • Page 120: 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 121 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 122: How To Use Battery Jumper Cables

    2. HOW TO USE BATTERY JUMPER CABLES 2. HOW TO USE BATTERY JUMPER CABLES If your lift truck battery is discharged (dead), you can start your lift truck by Jumping it from another lift truck that has a 24V negative-ground electrical system. The "Booster" battery must be fully charged and in good condition.
  • Page 123 Connect the jumper cables in the following To ground sequence: To starter switch ⓐ Connect a jumper cable from the positive Charged battery (+; red) terminal on one battery to the positive (+; red) terminal on the other battery. Never connect positive (+; red) to negative (-;...

  • Page 124: Planned Maintenance And Lubrication

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

  • Page 125: 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 126 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 127 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 128: Instructions Before Maintenance

    3. INSTRUCTIONS BEFORE MAINTENANCE 3. INSTRUCTIONS BEFORE MAINTENANCE 1) 1) INTERVAL OF 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...

  • Page 129: 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 130 5) 5) PERIODICAL REPLACEMENT OF SAFETY PARTS 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.

  • Page 131: Planned Maintenance Intervals

    4. PLANNED MAINTENANCE INTERVALS 4. PLANNED MAINTENANCE INTERVALS 1) 1) MAJOR COMPONENTS LOCATION MAJOR COMPONENTS LOCATION 9 10 11 15 12 14 160D7AOM21 Mast Transmission 17 Counterweight Lift cylinder 10 Torque converter 18 Radiator Steering unit 11 Engine 19 Seat Tilt cylinder 12 Steering cylinder 20 Cabin...
  • Page 132 2) 2) MAINTENANCE CHECK LIST MAINTENANCE CHECK LIST (1) (1) EVERY 10 HOURS SERVICE EVERY 10 HOURS SERVICE Check items Service Remarks Visual inspection ·Truck for obvious damage and leaks. Check, Repair or Replace 7-14 ·Warning plates and decals. Check, Replace 7-14 ·Condition of tires and wheels.
  • Page 133 INITIAL 50 HOURS SERVICE Check items Service Remarks Engine oil/filter (Initial 50 hours only) Change/Replace 7-19 INITIAL 100 HOURS SERVICE Check items Service Remarks Differential gear oil Change 7-41 Transmission oil and filter Replace 7-39 Brake cooling oil Change 7-43 EVERY 250 HOURS SERVICE Check items Service...
  • Page 134 Conventional hydraulic oil EVERY 5000 HOURS SERVICE EVERY 5000 HOURS SERVICE Check items Service Remarks Hydraulic oil (* Replace 7-33 Hyundai genuine long life hydraulic oil (10) (10) WHEN REQUIRED WHEN REQUIRED Check items Service Remarks Fuel system ·Fuel tank...

  • Page 135: Maintenance Chart

    5. MAINTENANCE CHART 5. MAINTENANCE CHART 1) 1) MAINTENANCE LOCATIONS MAINTENANCE LOCATIONS 160D7EMA011 CAUTION 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 136 Change 124.3 5000 Hours 21 Hydraulic oil Change 124.3 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 137: How To Perform Planned Maintenance

    6. HOW TO PERFORM PLANNED MAINTENANCE 6. HOW TO PERFORM PLANNED MAINTENANCE 1) 1) VISUAL INSPECTION 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.
  • Page 138 4) 4) FORKS 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 refer to below table. Fork length Height Model...

  • Page 139: Wheel And Tires

    6) 6) WHEEL AND TIRES WHEEL AND TIRES Check the condition of the drive and steering wheels and tires. Remove objects that are embedded in the tread. Inspect the tires for excessive wear and breaks or chunking out chunking out. Check all wheel lug nuts or bolts to be sure none are loose or missing.
  • Page 140 7) 7) TILTING CABIN TILTING CABIN Keep clearance of people except the operator Keep clearance of people except the operator before tilting the cabin. before tilting the cabin. Before tilting the cabin, make sure that the Before tilting the cabin, make sure that the mast is vertical or tilted forward.
  • Page 141 Do not operate the tilt control switch or any Do not operate the tilt control switch or any control parts while servicing under the tilted control parts while servicing under the tilted cabin. It can cause severe injury or death. cabin.

  • Page 142: Service Instruction

    7. SERVICE INSTRUCTION 7. SERVICE INSTRUCTION 1) 1) CHECK ENGINE OIL LEVEL CHECK ENGINE OIL LEVEL Dipstick 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.
  • Page 143 Apply a light film of lubricating oil to the gasket sealing surface before installing the filters. ※ Fill the filters with clean lubricating oil. Fill the filters with clean lubricating oil. 2609A6MA07 Install the filter to the filter head. ※ Mechanical over-tightening may distort the Mechanical over-tightening may distort the threads or damage the filter element seal.
  • Page 144 3) 3) CHECK COOLANT LEVEL 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 145 Wait until the temperature is below 50˚C Wait until the temperature is below 50˚C (122˚F) before removing the coolant system (122˚F) before removing the coolant system pressure cap. pressure cap. Failure to do so can cause personal injury Failure to do so can cause personal injury from heated coolant spray.
  • Page 146 ③ Fill the cooling system with clean water. ※ Be sure to vent the engine and aftercooler Be sure to vent the engine and aftercooler for complete filling. for complete filling. ※ Do not install the surge tank cap or the new Do not install the surge tank cap or the new coolant filter.
  • Page 147 160D7A6MI02 6) 6) CHECK CHARGE AIR COOLER CHECK CHARGE AIR COOLER Inspect the charge air cooler for dirt and debris blocking the fins. Check for cracks, holes, or other damage. If damage is found, please contact Hyundai distributor. 160D7A6MA21 7-24...
  • Page 148 7) 7) FAN BELT FAN BELT An deflection method can be used to check belt tension by applying 11.3 kgf (25 lbf) force between the pulleys on V-belts. If the deflection is more than one belt thickness per foot of pulley center distance, the belt tension must be adjust- 2609A6MA46 Inspect the fan belt for damage.
  • Page 149 9) 9) FAN BELT TENSIONER FAN BELT TENSIONER With the engine stopped, check the tensioner arm, pulley, and stops for cracks. If any cracks are found, the tensioner must be replaced. 2609A6MA23 With the belt installed, verify that neither tension- er arm stop is in contact with the spring case stop.

  • Page 150: Cleaning Of Air Cleaner

    CLEANING OF AIR CLEANER CLEANING OF AIR CLEANER (1) (1) Primary element Primary element ① Open the cover and remove the element. ② Wipe all contaminant and debris from inside the housing body. ③ Do not clean the filter element by striking or hitting the filter against any object to shake the debris from the filter element.
  • Page 151 FUEL TANK FUEL TANK Fill fuel fully when system the operation to Fuel Cap 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 drain cock. ※...

  • Page 152: Replacement Of Fuel Filter

    REPLACEMENT OF FUEL FILTER REPLACEMENT OF FUEL FILTER Clean around the filter head, remove the filter Bracket and clean the gasket surface. Replace the O-ring. ※ Make sure O-ring does not stick to filter head. Filter head Remove O-ring with screwdriver if necessary. Apply engine oil on the gasket of filter when mounting, and tighten 1/2 to 3/4 turn more after Cartridge...
  • Page 153 CRANKCASE BREATHER FILTER CRANKCASE BREATHER FILTER ※ Do not use pneumatic tools to remove the Do not use pneumatic tools to remove the Capscrew breather cover capscrews. Damage to the breather cover capscrews. Damage to the rocker cover can result. rocker cover can result.
  • Page 154 If the gasket was removed, install the gasket into the rocker lever cover groove starting with the tab end first. Then install the corners opposite the gasket tab end. Finish by pushing in the sides (see illustration). Gently push the gasket down into the groove. Do not used a finger to trace the gasket around into the groove during installation, as this will stretch the gasket, making it difficult to fully seat into the...
  • Page 155 LEAKAGE OF FUEL LEAKAGE OF FUEL Be careful and clean the fuel hose, injection Be careful and clean the fuel hose, injection FIRE pump, fuel filter and other connections as the pump, fuel filter and other connections as the leakage from these part can cause fire. leakage from these part can cause fire.

  • Page 156: Filling Hydraulic Oil

    FILLING HYDRAULIC OIL FILLING HYDRAULIC OIL Air breather Stop the engine to the position of level check. 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 157 CLEANING AND REPLACING RETURN CLEANING AND REPLACING RETURN FILTER FILTER Clean and replace the return filter in the following manner. Flange Remove the flange by loosening the mounting bolt. Remove return filter from the tank. Replace the return filter element with new one. Return filter Install the cover on the tank.
  • Page 158 CLEANING BRAKE LINE FILTER CLEANING BRAKE LINE FILTER Cut-off valve Remove the strainer from the filter body. Wash the strainer with cleaning oil. Install and tighten using specified torque. ·Tightening torque : 6~8 kgf·m (43.4~57.9 lbf·ft) 160D7EMI24 LUBRICATE RCV LEVER LUBRICATE RCV LEVER Bellows Remove bellows and grease the joint (A) and the...

  • Page 159: Tire Pressure

    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...

  • Page 160: Replacement Of Tire

    Do not use recycled wheel parts. Do not use recycled wheel parts. When removing lockering or inflating tire, use When removing lockering or inflating tire, use safety cable or chain to ensure safety. safety cable or chain to ensure safety. B e s u r e t o bl e e d a i r b e fo r e r e m ov i n g B e s u r e t o bl e e d a i r b e fo r e r e m ov i n g lockering.
  • Page 161 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 (3) (3) Direction of tire to be installed Direction of tire to be installed ①...

  • Page 162: Check Transmission Oil Level

    CHECK TRANSMISSION OIL LEVEL CHECK TRANSMISSION OIL LEVEL The oil level check must be carried out as follows; Oil level check (weekly). At horizontally standing machine. Transmission in neutral position. In cold start phase, the engine must be running about 2~3 minutes at idling speed, and the marking on the oil level gauge must then be lying above the cold start mark COLD.
  • Page 163 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 164 CLEANING TRANSMISSION AIR BREATHER 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 CHECK AND SUPPLYING AXLE OIL Move the machine to flat ground. Air breather Open the axle air breather to relieve internal air pressure.
  • Page 165 If the oil level is below the plug hole, supply oil Planetary gear through a plug hole. When checking the oil level, press the When checking the oil level, press the parking brake switch and fix front and rear parking brake switch and fix front and rear Plug frames using the safety lock bar.
  • Page 166 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. As the machine is hot after operation, wait As the machine is hot after operation, wait until the temperature has dropped.
  • Page 167 LUBRICATION LUBRICATION Supply grease through the grease nipple, using grease gun. After lubricating, clean off spilled grease. Press the parking brake switch and fix front Press the parking brake switch and fix front and rear tires with blocks. and rear tires with blocks. Set the mast and forks in a stable position Set the mast and forks in a stable position and turn the hydraulic safety lock valve into...
  • Page 168 MAINTENANCE OF WORK EQUIPMENT 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 169: Electrical System

    8. ELECTRICAL SYSTEM 8. ELECTRICAL SYSTEM 1) 1) WIRING, GAUGES WIRING, GAUGES C h e c k r e g u l a r l y a n d r e p a i r l o o s e o r malfunctioning gauges when found.

  • Page 170: Air Conditioner And Heater

    9. AIR CONDITIONER AND HEATER 9. AIR CONDITIONER AND HEATER 1) 1) CLEANING AND REPLACING FILTER CLEANING AND REPLACING FILTER Recircular ※ Always stop the engine before servicing. Always stop the engine before servicing. plenum assy Open the door, loosen the wing bolt and remove the recircular plenum assembly.

  • Page 171: 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 172: 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 173: Transmission Oil

    OSHA approved eye protection rated for 200 OSHA approved eye protection rated for 200 kPa kPa (30 (30 psi psi) is required for air cleaning ) is required for air cleaning operation. operation. Replace element if exhaust is black, or if lack of engine power is noted even after cleaning Replace element if exhaust is black, or if lack of engine power is noted even after cleaning or element.

  • Page 174: Differential Case

    5) 5) DIFFERENTIAL CASE DIFFERENTIAL CASE (1) (1) Differential oil 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.

  • Page 175: Hydraulic Tank

    6) 6) HYDRAULIC TANK HYDRAULIC TANK (1) (1) Hydraulic oil change 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.

  • Page 176: 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 using the correct tools and procedures. For details of procedures, contact your HYUNDAI dealer.
  • Page 177 When jacking up the truck, always check When jacking up the truck, always check carefully that the jack does not come out of carefully that the jack does not come out of position. position. When jacking up the truck, never When jacking up the truck, never go under the truck.

  • Page 178: Fuses Replacement

    FUSES REPLACEMENT FUSES REPLACEMENT Fuse box #1 No. Capacity Color Related electrical component ① START KEY ① Start key 시동키 TCU(B + ) ② FUSE HOLDER ③ ② Turn lamp TCU(B+) OPSS(B + ) T/M 컨트롤러 ④ ECU(B + ) ⑤...

  • Page 179: Functional Tests

    LAMP BULBS REPLACEMENT 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 After checking that the fuse is not blown and that there is no disconnection in the wiring harness, replace the lamp bulb.
  • Page 180 (4) (4) Service brakes and inching pedal 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.
  • Page 181 (8) (8) Steering system Steering system ※ The steering system, steering axle, and steering linkage on your truck should be inspected 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 periodically for abnormal looseness and damage, leaking seals, etc..
  • Page 182 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 183 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 184: Air Cleaning

    (rear end). Clean and lubricate the mast trunnion bushings. (3) (3) Lift chains Lift chains Lubricate the entire length of the mast rail lift and carriage chains with HYUNDAI chain and cable lube. AIR CLEANING AIR CLEANING Always maintain a lift truck in a clean condition. Do not allow dirt, dust, lint, or other contaminants to accumulate on the truck.
  • Page 185 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 186 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 187: Handling Truck In Extremely Hot Places

    11. HANDLING TRUCK IN EXTREMELY HOT PLACES 11. HANDLING TRUCK IN EXTREMELY HOT PLACES Pay careful attention particularly to the following Radiator points when handling the truck in extremely hot places. Compressed Scale and rust form more easily in the cooling air gun system, so wash with anticorrosion liquid.

  • Page 188: Cold Weather Operation

    12. COLD WEATHER OPERATION 12. COLD WEATHER OPERATION 1) 1) PREPARATION FOR LOW TEMPERATURE PREPARATION FOR LOW TEMPERATURE Replace lubrication oil with oil of the prescribed Min ambient temperature -5 -10 -15 -20 -25 -30 -50 viscosity. (˚C ) Fuel of low pour point must be used. ASTM Amount of 25 30 35 40 45 50 60 D975 No.1 diesel fuel should be used at...

  • Page 189: Recommendation Table For Lubricants

    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 VG46/VG68, Hyundai genuine long life hydraulic oil ★1 ISO VG15, Conventional hydraulic oil Grease Lithium base grease NLGI No.2 Fuel ASTM D975-No.2...

  • Page 190: Fuel And Lubricants

    14. FUEL AND LUBRICANTS 14. FUEL AND LUBRICANTS Capacityℓ (U.S. gal) Ambient temperature˚C (˚F) Service point Kind of fluid 110D-7A 160D-7A (-58) (-22) (-4) (14) (32) (50) (68) (86) (104) 130D-7A ★ SAE 5W-40 SAE 30 Engine oil 14.2 14.2...

  • Page 191: Specifications

    8. SPECIFICATIONS 8. SPECIFICATIONS 1. SPECIFICATION TABLE 1. SPECIFICATION TABLE C' C 160D7ASP011 Model Unit 110D-7A 130D-7A 160D-7A Capacity kg (lb) 11,000 (25000) 13,000 (29000) 16,000 (36000) ← ← Load center mm (in) 600 (24") Weight(Unloaded) 15628 (34450) 16383 (36120) 19220 (42370) ←...

  • Page 192: Specification For Major Components

    2. SPECIFICATION FOR MAJOR COMPONENTS 2. SPECIFICATION FOR MAJOR COMPONENTS 1) 1) 110/130D-7A 110/130D-7A (1) (1) ENGINE ENGINE Item Unit Specification Model Cummins QSB6.7 Type 4 cycle turbocharged, charger air cooled diesel engine Cooling Method Water cooling Number of cylinders and arrangement 6 cylinders, In-line Firing order 1-5-3-6-2-4...

  • Page 193: Steering Unit

    (4) (4) STEERING UNIT STEERING UNIT Item Unit Specification Type Load sensing/Non load reaction/Dynamic signal Capacity cc/rev Rated flow 45.4 (5) (5) POWER TRAIN DEVICES 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...
  • Page 194 2) 2) 160D-7A 160D-7A (1) (1) ENGINE ENGINE Item Unit Specification Model Cummins QSB6.7 Type 4 cycle turbocharged, charger air cooled diesel engine 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 ×...
  • Page 195 (4) (4) STEERING UNIT STEERING UNIT Item Unit Specification Type Load sensing / Non load reaction / Dynamic signal Capacity cc/rev Rated flow 45.4 (5) (5) POWER TRAIN DEVICES POWER TRAIN DEVICES Item Specification Model F&S 300* OZG 040 / 18 (ZF SACH) Torque converter Type 3 Element, 1 stage, 2 phase...

  • Page 196: Tightening Torque

    3. TIGHTENING TORQUE 3. TIGHTENING TORQUE 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±0.5 65.1±3.6 MCV mounting bolt, nut M10×1.5 6.9±1.4 49.9±10.1 Hydraulic system Steering unit mounting bolt M10×1.5...

  • Page 197: Troubleshooting

    9 . TROUBLESHOOTING 9 . TROUBLESHOOTING 1. ENGINE SYSTEM 1. ENGINE SYSTEM Trouble symptom Probable cause Remedy ·Low oil level in oil pan. ·Add oil. Oil pressure caution lamp fails ·Oil filter element clogged. ·Replace element. to go out. ·Loose or worn oil pipe joint leaks oil. ·Check and repair.

  • Page 198: Electrical System

    2. ELECTRICAL SYSTEM 2. ELECTRICAL SYSTEM Trouble symptom Probable cause Remedy ·Faulty wiring. ·Check for loose terminal and discon- Lamps dimming even at maxi- mum engine speed. nected wire. ·Improper belt tension. ·Adjust belt tension. Lamps flicker during engine operation. ·Charge lamp defective.

  • Page 199: Torque Flow System

    3. TORQUE FLOW SYSTEM 3. TORQUE FLOW SYSTEM Trouble symptom Probable cause Remedy 1. Excessive oil ·Improper oil level. ·Check oil level. Add or drain oil as temperature rise 1) Torque converter necessary. ·Impeller interfering with surroundings. ·After draining oil from oil tank and transmission, check and replace interfering parts.
  • Page 200 Trouble symptom Probable cause Remedy 3.Low output power ·Insufficient hydraulic pressure : 1) Torque converter - Check oil level and add oil - Low oil level. - Check joints and pipes. - Air sucked in. If necessary, retighten joint or repla- ce packing.
  • Page 201 Trouble symptom Probable cause Remedy 4.Unusual oil pressure ·Control valve malfunctioning. 1) Oil pressure is high (1)Check for spool operation. If necessary, replace valve. (2)Check for clogging of small hole in valve body. 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 202 Trouble symptom Probable cause Remedy ·Foreign matter intruding into oil pass- ·Disassemble, check and repair or 5. Power is not transmitted (Continue) age to clutch. replace. ·Shaft spline worn. ·Disassemble, check and replace. ·Oil leaks from oil seal. ·Disassemble and check for wear of 6.

  • Page 203: Steering System

    4. STEERING SYSTEM 4. STEERING SYSTEM Trouble symptom Probable cause Remedy ·Low oil pressure. ·Check locknut. Repair. 1. Steering wheel drags. ·Bearing faulty. ·Clean or replace. ·Spring spool faulty. ·Clean or replace. ·Reaction plunger faulty. ·Replace. ·Ball-and-screw assembly faulty. ·Clean or replace. ·Sector shaft adjusting screw excessi- ·Adjust.

  • Page 204: Brake System

    5. BRAKE SYSTEM 5. BRAKE SYSTEM Trouble symptom Probable cause Remedy ·Hydraulic system leaks oil. ·Repair and add oil. 1. Insufficient braking force ·Hydraulic system leaks air. ·Bleed air. ·Disk worn. ·Replace ·Brake valve malfunctioning ·Repair or replace. ·Hydraulic system clogged ·Clean.

  • Page 205: Hydraulic System

    6. HYDRAULIC SYSTEM 6. HYDRAULIC SYSTEM Trouble symptom Probable cause Remedy ·Seal inside control valve defective. ·Replace spool or valve body. 1. Large fork lowering speed. ·Oil leaks from joint or hose. ·Replace. ·Seal inside cylinder defective. ·Replace packing. ·Tilting backward : Check valve defec- ·Clean or replace.

  • Page 206: Testing And Adjusting

    10. TESTING AND ADJUSTING 10. TESTING AND ADJUSTING 1. ENGINE SYSTEM 1. ENGINE SYSTEM 1) 1) EASE OF STARTING, NOISE 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.

  • Page 207: 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 208 7) 7) Move fan backwards and forwards by hand to check for looseness. Tighten mounting bolt with a spanner. Crack 160D7TA11 10-3...

  • Page 209: Drive System

    2. DRIVE SYSTEM 2. DRIVE SYSTEM 1) 1) GEAR SHIFT LEVER GEAR SHIFT LEVER (1) (1) Neutral starting Neutral starting Engine can be started only when the shifting lever is in neutral position. (2) (2) Shifting FWD/REV lever Shifting FWD/REV lever ①...
  • Page 210 (3) (3) Inching pedal 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, 22 mm (0.9 in).

  • Page 211: Travel System

    3. TRAVEL SYSTEM 3. TRAVEL SYSTEM TIRES 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 212: Steering System

    4. STEERING SYSTEM 4. STEERING SYSTEM STEERING WHEEL 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 steer ing wheel movement before rear wheel starts to move. Range should be 30 ~ 60 mm at rim of steering wheel.

This manual is also suitable for:

130d-7a160d-7a

Table of Contents