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

2. OPERATING HAZARDS

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

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

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

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

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

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

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

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

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

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

11. Drop-offs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-7

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. Cluster indication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-11

CONTENTS

Table of Contents

Need help?

Do you have a question about the 100D and is the answer not in the manual?

Questions and answers

Summary of Contents for Hyundai 100D

Page 1: Table Of Contents
CONTENTS 1. SAFETY HINTS 1. Daily inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 2.
Page 2 6. Switches - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-16 7.
Page 3 8. Electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-43 9.
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. "VIEW"(RADIATOR TOP) CABIN RCV LEVER CABIN INSIDE - RH 30 31 160D7OM101 Logo 11 Loading truck(hanger) 22 Attach Fork 13 Non slip...
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 CAP(Item 7) This warning label is positioned on the radiator. Never open the filler cap while engine running or at high coolant temperature. 91FJ-00190 160D7OM100 HAND CAUTION(Item 8) This warning label is positioned on the top side of mast. It warns of the danger of injury from movement between rails, chains, sheaves, fork carriage, and other parts of...
Page 11: Safety Instructions
SAFETY INSTRUCTION(Item 16) Truck for USA or equipped with *OPSS. This warning label is positioned on the inside of cabin door if the truck is for USA or equipped with *OPSS. SAFETY INSTRUCTIONS This forklift is equipped with an operator This forklift is equipped with an operator existence sensing system per ANSI/ASME existence sensing system per ANSI/ASME...
Page 12: Engine Serial Number
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 13: 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 14: 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 15 Don't operate the truck outdoors in rainy day. xclude the truck equipped cabin. 160D7OM07 Exhaust gas is dangerous. Do not operate the truck at the inhouse, if possible. Provide adequate ventilation when working in a closed space. 160D7OM08...
Page 16: Seat Belts
3. SEAT BELTS Always buckle up for the truck equipped with safety belt. 160D7OM09 Seat belts can reduce injuries. 160D7OM11...
Page 17: No Riders
4. NO RIDERS The operator is the only one who should be on a truck. 160D7OM12 Never transport personnel on the forks of a lift truck. 160D7OM14...
Page 18: 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. 160D7OM05 Watch for people in your work area even if your truck has warning lights or alarms.
Page 19: 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. 160D7OM16...
Page 20: 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. 160D7OM14 Always lower the load slowly. Raise and lower with mast vertical or tilted slightly back(Never forward).
Page 21: Pinch Points
8. PINCH POINTS Keep hands, feet and legs out of the mast. D255OM61 Don't use the mast as a ladder. 160D7OM62 Never try to repair the mast, carriage, chain, or attachment by yourself. Always get a trained mechanic. 160D7OM63...
Page 22: 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. 160D7OM18 When handling bulky loads that restrict your vision operate your truck in reverse to improve visibility.
Page 23: Grades, Ramps, Slopes And Inclines
10. GRADES, RAMPS, SLOPES AND INCLINES Never turn on a grade, either loaded or unloaded. Unloaded-Forks downgrade 160D7OM30 Loaded - Forks upgrade 160D7OM33 1-11...
Page 24: 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 25 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 26: Surface And Capacity
12. SURFACE AND CAPACITY Avoid these conditions. They can cause a truck to tip over or lose traction for braking or driving. Know the weight of your truck and load. Especially when using elevators, Know the capacity of the elevator you intend to SAND use.
Page 27: Parking
13. PARKING Never park on a grade. 160D7OM41 Always come to a complete stop before leaving truck. Be sure travel control is in NEUTRAL. 160D7OM42 Lower forks fully to floor and tilt forward. 160D7OM44 Set parking brake. Position 1 : OFF(Release) Position 2 : ON(Lock) Turn key to OFF position.
Page 28: Refueling
14. REFUELING Before adding oil, check around truck for oil leakage. 160D7OM47 Keep away from fire when adding oil or during operation. 160D7OM48 After adding oil, wipe off any oil spilled on truck. 160D7OM49 1-16...
Page 29: Step
15. STEP When getting on or off the truck, use the step provided. 160D7OM50 Do not jump up or down from the truck. 160D7OM52 1-17...
Page 30: 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. 160D7OM18 Parking brake must be locked in the PARK POSITION before exiting from the vehicle. 1.
Page 31: Operating Hazards
2. OPERATING HAZARDS 1. LOOSE LOADS Loose or unbalanced loads are dangerous. Observe these precautions. Never carry loose or uneven material. 160D7OM53 Center wide loads. 160D7OM55 Stack and band loose material. D35AOM41 Avoid sudden braking or starting When the truck is loaded, do not drive at maximum speed.
Page 32: 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 33: Low Overhead Clearance
4. LOW OVERHEAD CLEARANCE Know the height of your truck, with and without a load. Check your clearances. Keep the load low and tilted back. 160D7OM73 Watch overhead clearance: Moving into overhead structures can tip a truck over, or spill a load. 160D7OM74 5.
Page 34: Right Angle Stacking
6. RIGHT ANGLE STACKING When right angle stacking or moving with a raised load to clear low objects, avoid sharp turns and move slowly. 160D7OM75 7. CHAIN SLACK Slack chains mean rail or carriage hang- Raise the forks before you move, or broken chains can result.
Page 35: 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 36: Lifting Loads
10. LIFTING LOADS Never permit any persons to stand or pass under lifted load. 160D7OM58 Never use wire rope to lift a load. 160D7OM60...
Page 37: Drop-Offs
11. DROP-OFFS To avoid these hazards, you must: Talk to the truck driver yourself: make sure the driver does not move the trailer until you are done. Apply trailer brakes. Use wheel chocks. Use trailer-to-dock locking system if available. D35AOM48 The impact of moving in and out of a trailer may cause the trailer to creep or move.
Page 38: Know Your Truck
3. KNOW YOUR TRUCK 1. GENERAL LOCATIONS 100D/120D/135D/160D-7 160D7OM54 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...
Page 39: 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 40 OPERATOR SAFETY WARNING DECAL Watch out for Buckle up ! Prevent overturns! In case of Hold on other people Tip Over : tight Don't jump Apply brake when Brace feet leaving truck Lean away Read the manual Most lift truck AVOID : INJURIES are to other slippery, sloping,...
Page 41: 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. CABIN CEILING Rear Radio and cassette...
Page 42: Cluster
4. CLUSTER 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. Pilot lamp : Indicate operating status of the truck.
Page 43: Fuel Gauge
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 44 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 45 Immediately pull the truck to a convenient stop. Stop the engine. Investigate the cause. Consult a HYUNDAI dealer to investigate the cause. 77073CD19 Do not operate until the cause has been corrected.
Page 46: Water In Fuel Warning Lamp
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 BATTERY CHARGING WARNING LAMP This lamp is ON after key switch is turned ON. Check the battery charging circuit when this lamp comes ON during engine operation.
Page 47 T/M ERROR, HOUR METER, ENGINE RPM INDICATOR FND and LED displaying T/M error, engine RPM and hour meter. T/M MESSAGE It displays T/M error codes through CAN (Controller Area Network) calibrator, messages from inching or AEB operation, total work hours and engine rpm. HOURMETER ⋅...
Page 48 5.TRANSMISSION MESSAGE INDICATOR INCHING Inching sensor initializing Synchronize inching pedal & linkage with inching sensor. Initializing inching sensor. Symbol Meaning Remark Prepare for initialization(1) - Place the truck on the level floor, release parking brake and set the gear to neutral. (Before releasing parking brake, install block under the wheels for safety.) Prepare for initialization(2) - With the truck stopped, turn the start key...
Page 49 Symbol Meaning Remark - Truck is not stopped. (After stopping the truck, restart initialization) - Gear not on the neutral. (After putting gear to neutral, restart initializat- ion) - Narrow gap between angle and pedal - Wide gap between angle and pedal - Voltage of inching sensor(AU1) is out of standard.(Need adjustment) - Signals of sensor No 1 and No 2 are different.
Page 50 AEB(Initializing transmission efficiency) AEB(Automatische Ermittlung der Berfullparameter) To minimize gear shift impact by manufacture tolerance of each transmission, measure the play of disc inside the clutch assembly and compensate it to keep optimal performance. AEB(Initializing transmission efficiency) operation principle TCU(T/M Control Unit) sensing the signals from speed sensor calculates each of clutch discs, whenever oil is charged into clutch, and compensates the oil charging pressure and time.
Page 51 Symbol Description Remark - Initializing 3rd gear clutch. - Completion of initialization. T/M MESSAGE - Restart in 1~3 seconds after key OFF. - Low engine rpm. T/M MESSAGE - Slowly step on the accelerator pedal. - High engine rpm. T/M MESSAGE - Slowly step off the accelerator pedal.
Page 52 Normal sequence of AEB operation. In normal operation, it indicates in the order of "ST > KR > KV > K1 > K2 > K3" and takes 3~5 minutes. After AEB is completed successfully, it displays "OK". After completing AEB, turn ON the start switch again after turning OFF the switch. In case of error, rerun AEB.
Page 53: Switches
6. SWITCHES Work light switch Inc/Dec switch Hazard switch Inching switch Diagnostic switch Main light switch Auto idle switch Auto/Manual select switch Start switch Rear wiper/washer switch Parking brake switch Horn button Multi function switch Cabin tilt switch STOP DOWN * Cabin tilt switch location : Refer to page 7-17.
Page 54: Hazard Switch
HAZARD SWITCH Use for parking, or loading truck. If the switch is left ON for a long time, the battery may be discharged. 160D7CD42 INCHING 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 If this switch is pressed, the parking brake is applied and the gauge...
Page 55: Diagnostic Switch
ECU automatically flash faults codes. 9) INC/DEC SWITCH is used to sequence forward or backward through the active faults. 160D7CD51 AUTO IDLE SLOITCH Machine serial No. 100D-7(#0023-) 120D-7(#0007-) 135D-7(#0009-) 160D-7(#0027-) This switch is used to raise the idle rpm to 1200rpm automatically. 160D7CD55 3-18...
Page 56: Horn Button
CABIN TILT SWITCH Tilting UP cabin Press the top of the switch fully to tilt the cabin upward. STOP DOWN STOP the tilting operation(Default) Release the switch to stop the tilting operation. Titilting DOWN cabin 160D7CD74 Press the bottom of the switch fully to tilt the cabin downward. Refer to page 7-16 for cabin tilting procedure.
Page 57: Control Device
7. CONTROL DEVICE Steering wheel lever Steering wheel Gear selector lever Remote control lever Hyd safety lock lever Inching pedal Brake pedal Accelerator pedal 160D7CD08 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 58 GEAR SELECTOR LEVER This lever is used for gear selection, forward 3 stages and reverse 3 Acceleration stages. Deceleration If you push the gear selector lever, the truck moves forward, but pulling the gear selector lever, the truck moves backward. Forward If you turn the gear selector lever forward, the truck increases the Backward...
Page 59 STEERING WHEEL LEVER By pulling down the lever, the wheel is adjustable to tilt. By pulling up the lever, the wheel is adjustable to telescope. 160D7CD70 HYDRAULIC SAFETY LOCK LEVER When the lever is turned to LOCK position, the hydraulic pilot line will be cut off, so the work equipment will not operate.
Page 60: 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. Air conditioner switch AIR CONDITIONER Temperature control knob Fan speed control knob Cabin ceiling Cabin ceiling Air outlet 160D7CD90 3-23...
Page 61: Temperature Control Knob
AIR CONDITIONER SWITCH(Compressor switch) This switch turns ON or OFF the air conditioner. When this switch is OFF, heater operates. 160D7CD53 TEMPERATURE CONTROL KNOB This knob regulates the temperature of air. - Left side (red zone) : Heat up air temperature - Right side (blue zone) : Cool down air temperature If the air conditioner switch is OFF, cool air cannot be generated , even if this knob indicates the blue zone.
Page 62: Others
9. OTHERS Rear Radio and cassette Front Cabin Air conditioner roof Engine controller(ECM) Transmission Operator seat control unit(TCU) Fuse box Cigar lighter Master switch 160D7CD09 3-25...
Page 63: Cigar Lighter
1 1 ) 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.
Page 64: Master Switch
USE BOX Fuse box #1 The fuses protect the electrical parts and wiring from burning out. CASSE FENDER BACK- ILLUM. C L U S T E R TTE- WORK The fuse box cover indicates the capacity of each LAMP RADIO LAMP fuse and circuit it protects.
Page 65 RADIO AND CASSETTE(Standard) SOUND MUTE BAND JAZZ VOCAL POP CLASSIC DISC VOLUME ROCK FLAT LOUD PRESET VOLUME 7807A3CD81 FRONT PANEL PRESENTATION - - - - - - - - Preset button 1 11 RDS - - - - - - - - - - Long press : RDS on/off - - - - - - - - Preset button 2 BAND - - - - - - - Short press : To select band - - - - - - - - Preset button 3...
Page 66: Power On/Off
AUDIO Power and mute button POWER ON/OFF Press to switch on the set. Press for more than 2 seconds to switch off the set. MUTE(Silence) Short press key to mute or cancel the mute(silence). MUTE 7807A3CD09A The silence period may be interrupted by ALARM announcement or traffic announcement messages(If TA is switched on).
Page 67: Automatic Search
AST button Press AST to select the desired source : - TUNER BAND - CASSETTE Products with cassette mechanism will change source to cassette only when a tape is inserted. 160D7CD13 RADIO Wave band / Automatic search button WAVE BAND Press BAND to select the desired band: BAND FM I...
Page 68 Preselected button Preselected stations Manually storing stations in a preset Five stations per band can be stored and recalled using the preset keys(1 to 5). Tune in to the desired station. 7807A3CD14 Press the desired preset key(1 to 5) for more than 2 seconds to store the current tuned station.
Page 69 ADIO DATA SYSTEM(RDS) ON FM More and more stations broadcasts RDS informations in order to offer you many advantages including: Program service name(PS) Allows the radio to display the name of the station instead of its frequency. 7807A3CD15 Automatic returning(AF) The set remains tuned to the current station by continually searching the best alternative frequency for best reception.
Page 70: Cassette Player
CASSETTE PLAYER Winding/Rewinding button Only use good quality cassettes. To avoid possible tape damage always take out the cassette after use. Protect your cassettes. Put them back in their boxes immediately after use. Never expose cassettes to heat or direct sunlight. 7807A3CD12 Play back Slide the cassette, with the open side to the right into the cassette...
Page 71: Radio Setting
RADIO SETTING AMERICA Press , No. 1 and No. 4 buttons at the same time. Set up completes displaying " AMERICA". JAZZ VOCAL POP CLASSIC ROCK FLAT LOUD PRESET SOUTH AMERICA Press , No. 2 and No. 5 buttons at the same time. Set up 7807A3CD16 completes displaying "...
Page 72: 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 73: 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 74: 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 75: 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 76: 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 77: 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 78: 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 79: 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 80: 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 160D7OM15A alternator belt must be replaced.
Page 81: Check Hydraulic Oil Level
In accordance with the mast equipped, the oil level differs. Lower limit Gauge V - mast TF - mast Model (U.S.gal) Level gauge 111(29) TF370 ~ TF600 100D-7/ Lower limit V300 ~ V700 160D7MA14 Upper limit 120D-7 123(32) TF370 ~ TF600 111(29) V300 ~ V600 Lower limit...
Page 82 CHECK PEDALS Check for any catching or abnormal heaviness when depressing the pedals. Inching pedal Free play : 10 degree Interlock stroke with brake pedal : 10 degree Brake pedal Free play : 10 degree...
Page 83: 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 Pull lever A to adjust seat forward or backw- ard.
Page 84: Starting From A Safe Condition
5. STARTING FROM A SAFE CONDITION Always start from a safe condition. Before operating a lift truck, make sure that : You are safely seated in the truck. Seat belt is buckled up. Parking switch ON The parking brake is applied. The forks are fully lowered to the floor or ground.
Page 85: 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 86: Starting And Stopping The Engine
7 7 . STARTING AND STOPPING THE ENGINE CHECK INDICATOR LIGHTS Check if parking brake switch is ON. Gear selector lever Check if gear selector lever is in neutral position. Parking brake switch Check if hydraulic safety lever is in the lock Hydraulic safety lever position.
Page 87 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 88 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 89: 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 90: 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 Hydraulic safety lever hydraulic oil temperature is below 25 C (77 F ).
Page 91: 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 92 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 93: 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. 160D7OP10 Traveling operation When warm-up operation is completed after the Gear selector lever engine is started, move the truck according to the following procedure.
Page 94 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. Avoid changing direction at high speed. urning the truck Turn the truck by moving the steering wheel into the desired direction.
Page 95 Stopping the truck Press the brake pedal to stop the truck. Gear selector lever Put the gear selector lever in the neutral Parking brake switch position. Hydraulic safety lever Press the parking brake switch. 160D7OP14 Lower the forks to the ground. Low idling for 5 minutes 160D7OP07...
Page 96 Stopping engine Gear selector lever If the engine is abruptly stopped before it has cooled down, its service life may be Parking brake switch shortened. Avoid sudden stop except an Hydraulic safety lever emergency. When the engine is overheated, do not stop immediately.
Page 97: 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 98 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 99: 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 100 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 101 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 102 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 103 STACKING To put a load on a stack Aproach slowly and align the lift truck and load squarely with the stack. D35AOM137 Raise the load as the lift truck nears the stack. D35AOM138 Move forward slowly until the load almost touches the stack. The leading edge and sides of the load pallet should line up exactly with the near edge and side of the load or rack on which you are stacking.
Page 104 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 105: 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 P WHEN YOU LEAVE YOUR TRUCK, OR PARK IT, FOLLOW THESE SAFELY RULES ARK IT, FOLLOW THESE SAFELY RULES Park in a safe area away from normal traffic.
Page 106: Storage
14. STORAGE 14. STORAGE 1) 1) BEFORE 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.
Page 107: 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 108: 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 with the machine as it should avoid touching with To lift bracket the truck body.
Page 109: 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 110 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 111: 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 112 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 113: 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 114: 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 115 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 116 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 117: 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 HOURMETER 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 118: 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 119 PERIODICAL REPLACEMENT OF SAFETY PARTS These are the parts which the operator cannot judge the remained lifetime of them by visual inspection. Repair or replace if an abnormality of these parts is found even before the recommended replacement interval. Replacement of consumable service parts is not covered under warranty. Periodical replacement of safety parts Interval Every 2 to 4 years...
Page 120: Planned Maintenance Intervals
4. PLANNED MAINTENANCE INTERVALS MAJOR COMPONENTS LOCATION 160D7OM21 Mast Transmission 17 Counterweight Lift cylinder 10 Torque converter 18 Radiator Steering unit 11 Engine 19 Seat Tilt cylinder 12 Steering cylinder 20 Cabin Main control valve 13 Hydraulic pump 21 Steering wheel Fork 14 Steering axle 22 Muffler...
Page 121 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 7-14 Warning plates and decals. Check, Replace Condition of tires and wheels. Air pressure. 7-15 Check, Refill or Replace Lift chain and fastener.
Page 122 INITIAL 100 HOURS SERVICE Check items Service Remarks Differential gear oil Change 7-37 Transmission oil and filter Replace 7-35 Brake cooling oil Change 7-39 EVERY 250 HOURS SERVICE Check items Service Remarks 7-37 Differential gear oil Check, Refill Lubrication 7-57 Lift chain Check, Lubricate 7-57...
Page 123: When Required
WHEN REQUIRED Check items Service Remarks Fuel system 7-24 Fuel tank Drain or Clean 7-26 Water separator Drain or Clean 7-25 Fuel filter Replace Engine lubrication system 7-16 Engine oil Replace 7-16 Engine oil filter cartrige Replace Engine cooling system 7-18 Coolant Refill, Replace...
Page 124: Maintenance Locations
5 5 . MAINTENANCE CHART MAINTENANCE LOCATIONS 160D7MA011 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 125: Maintenance Chart
MAINTENANCE CHART Service Item Service Service Description Capacity( ) interval Action symbol point No. Pedal linkage operation Check, Adjust Drive rim & Tire air pressure Check, Add Horn operation Check, Replace Lamp operation Check, Replace Transmission oil level Check, Add Fuel level Check, Add Water separator...
Page 126: 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 127 Fork length Height Model (mm) difference(mm) below 1500 Height difference 100D/120D/135D/160D above 1500 D35AOM150 If the fork blade at the heel is worn down by more than 10%, the load capacity is reduced and the fork must be replaced. Shank Inspect the forks for twists and bends.
Page 128: Wheel And Tires
Check with a mechanic. The tire may require removal and repair. Incorrect (low) tire pressure can reduce the stability of your lift truck. Do not operate truck with low tire pressure. 160D7OM153 Proper cold inflation 100D/120D-7 : 785kpa(114psi) 135D/160D-7 : 853kpa(124psi). 7-16...
Page 129 TILTING CABIN Keep clearance of people except the operator before tilting the cabin. Before tilting the cabin, make sure that the mast is vertical or tilted forward. Otherwise, the operation could be blocked by mast tilt cylinders. Locate the truck on the plain and stable floor. Apply parking brake before servicing.
Page 130 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 160D7MI64 The angle of fully tilted cabin is 65 and the safety lock function operates within the tilting angle of 20 .
Page 131: Service Instruction
7. SERVICE INSTRUCTION CHECK ENGINE OIL LEVEL Check the oil level with the machine on a flat Engine oil fill ground before starting engine. Pull out the dipstick and wipe with a clean cloth. Check the oil level by inserting the dipstick completely into the hole and pulling out again.
Page 132 Apply a light film of lubricating oil to the gasket sealing surface before installing the filter. Fill the filter with clean lubricating oil before installation. 7803A6MI07 Install the filler to the filter head. Mechanical over-tightening may distort the threads or damage the filter element seal. 160D7MI03 Clean and inspect the oil drain plug threads and the seal surface.
Page 133 (10) Operate the engine at low idle and inspect for leaks at the filter and the drain plug. Shut the engine off and check oil level with dipstick. Allow 15 minutes for oil to drain down before checking. Do not overfill the engine with oil. 160D7MI05 CHECK COOLANT LEVEL Check the coolant level at reservoir tank.
Page 134 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. 77076MI37 Protect the environment : Handling and disposal of used antifreeze can be subject to...
Page 135 The system must be filled properly to prevent air locks. During filling, air must be vented from the engine coolant passages. Wait 2 to 3 minutes to allow air to be vented; then add mixture to bring the level to the top. Adequate venting is provided for a fill rate of 19 liters/minute (5 U.S.gal/minute).
Page 136 Cooling system filling The system must be filled properly to prevent air locks. During filling, air must be vented from the engine coolant passages. Wait 2 to 3 minutes to allow air to be vented; then add mixture to bring the level to the top. The system has a design fill rate of 19 liters per minute (5 U.S.gallons per minute).
Page 137: 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 138 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 139: 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 Primary element...
Page 140: Replacement Of Fuel Filter
FUEL TANK Fill fuel fully when system the operation to Strainer & 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 plug. Be sure to LOCK the cap of fuel tank.
Page 141: Fuel Water Separator
Install the water sensor into the new fuel filter. Lubricate the O-ring with clean lubricating oil. Install the filter to the filter head. Tighten 3/4 of a turn after contact. Cartridge Mechanical overtightening can distort the threads or damage to filter element seal. Connect the water sensor to the wiring harness.
Page 142: Bleeding The Fuel System
BLEEDING THE FUEL SYSTEM Air in fuel Do not vent the fuel system on a hot engine; this can cause fuel to spill onto a hot exhaust manifold, which can cause a fire. The replacement of fuel supply lines, fuel filters, fuel injection pump, high-pressure fuel lines, and injectors will let air enter the fuel system.
Page 143 A source that is often overlooked for air to enter the fuel system is between the inlet of the prefilter and the suction tube in the tank. Fuel tanks that have the outlet fitting at the top have a suction tube that extends to the bottom of the tank.
Page 144: Hydraulic Oil Check
LEAKAGE OF FUEL Be careful and clean the fuel hose, injection FIRE !!! pump, fuel filter and other connections as the leakage from these part can cause fire. 75776MI16 HYDRAULIC OIL CHECK Level gauge Lower the forks on the ground at a flat location as in the illustration.
Page 145: Change The Hydraulic Oil
CHANGE THE HYDRAULIC OIL Lower the forks on the ground and extend the tilt breather cylinder to the maximum. Loosen the cap and relieve the pressure in the tank. Prepare a suitable drain pan. To drain the oil loosen the drain plug. After draining oil, tighten the drain plug.
Page 146 REPLACEMENT OF ELEMENT IN HYDRAULIC TANK BREATHER Loosen the cap and relieve the pressure in the breather tank. Loosen the screw and remove the cover. Pull out the filter. Replace the filter with new one. Air breather Screw Reassemble by reverse order of disassembly. Cover Tightening torque : 0.2~0.3kgf m(1.4~2.1lbf ft) Filter...
Page 147: Tire Pressure
Recommended tire pressure(When tire is cooled) Pressure Model Size Normal 8.0kgf/cm (114psi) 100D/120D-7 10.00-20, 16PR 8.7kgf/cm (124psi) 135D/160D-7 12.00-20, 20PR Continuous operation will produce heat and increase pressure on tire. But such phenomenon was already taken into account when designing a tire.
Page 148: Replacement Of Tire
Do not use recycled wheel parts. When removing lockering or inflating tire, use safety cable or chain to ensure safety. Be sure to bleed air before removing lockering. Never inflate tires unless the lockering is assembled in its place. Avoid the followings when traveling. Rubbing tires against road bank or rack at cargo-unloading spot.
Page 149 Loosen slightly all wheel mounting. Tools : Socket 32mm Torque wrench Extension bar Lift the machine with a jack. Loosen all wheel mounting nuts and replace the tire. Torque wrench 160D7MI37 Direction of tire to be installed Be careful that the valve should be facing the outside.
Page 150: Check Transmission Oil Level
CHECK TRANSMISSION OIL LEVEL The oil level check must be carried out as follows; oil level check(weekly). At horizontally standing machine. Transmission in neutral position. In cold start phase, the engine must be running about 2~3minutes at idling speed, and the marking on the oil level gauge must then be lying above the cold start mark COLD.
Page 151 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 152 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 153 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 154 Supply oil into the differential gear and the Differential gear planetary gear. Oil amount : 19 (5.0U.S. gal) (Differential gear)+2 1.7 (0.4U.S. gal) (Planetary gear) Supply oil until it overflows from the oil filler, then install the plug. s the machine is hot after operation, wait Fill &...
Page 155 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 156 MAINTENANCE OF WORK EQUIPMENT Lubricate to each point of working device. Lubricate the grease to grease nipple in accordance with lubrication intervals. Description Fork adjustment cylinder pin Fork shaft Tilt cylinder pin Load chain Mast support pin Chain sheave pin Shorten lubricating interval when working in the water or dusty place.
Page 157: 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 158: Air Conditioner And Heater
9. AIR CONDITIONER AND HEATER CLEANING AND REPLACING FILTER Always stop the engine before servicing. Remove the recircular plenum assembly by loosening the mounting bolts from the cabin Recircular ceiling. plenum assy 160D7MI58 Clean the recircular plenum using a pressurized air(Below 2kgf/cm , 28psi).
Page 159: Replacement And Check
10. REPLACEMENT AND CHECK 10. REPLACEMENT AND CHECK Check the battery condition per the table below. Recharge or service as shown by the indicator. Indicator Battery condition Mark Color Normal Green Discharged White Contamination/overcharge Black BATTERIES EMIT EXPLOSIVE GAS. Do not BATTERIES EMIT EXPLOSIVE GAS.
Page 160: 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 161 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 162: Transmission Oil
TRANSMISSION OIL Do not touch hot components or allow hot oil to contact your skin. Transmission oil Park the truck in a level place and lower the forks. Then stop the engine and apply the Dipstick parking brake. Oil level check Open inspection plate, and oil level can be checked using dipstick.
Page 163: 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 160D7OM28 Strainer Cleaning OSHA-approved eye protection rated for 200kPa(30psi) is required for air cleaning operation. When changing oil, remove strainer and clean it with flushing oil.
Page 164: Cooling System
The tires and rims should always be serviced or changed by trained personal using the correct tools and procedures. For details of procedures, contact your HYUNDAI dealer. Wear safety glasses and a face shield when using compressed air. Block the tire at the opposite corner from the tire to be replaced.
Page 165 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 166: Fuses Replacement
FUSES REPLACEMENT Fuse box #1 No. Capacity Color Related electrical component Brown Engine control module CASSE FENDER BACK- ILLUM. C L U S T E R TTE- WORK Yellow Cassette radio LAMP RADIO LAMP White Cluster Yellow T/M control unit SPARE (5A) SPARE (10A) SPARE (15A)
Page 167 LAMP BULBS REPLACEMENT Lamp Spec(24V) Head lamp Turn signal lamp Clearance lamp Stop lamp Backup lamp Warning lamp 1.4W Meter lighting lamp 3.4W 160D7OM69 License lamp (option) 3.4W Beacon lamp (option) Strobe type Rear work lamp After checking that the fuse is not blown and that there is no disconnection in the wiring harness, replace the lamp bulb.
Page 168 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 169 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 170 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 171 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 172: 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 173 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 174 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 175: 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 176: 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 Amount of...
Page 177: Recommendation Table For Lubricants
13. RECOMMENDATION TABLE FOR LUBRICANTS NEW TRUCK New truck uses following fuel, coolant and lubricant. 00D/120D/135D/160D-7 Description Specification Engine oil SAE 15W-40(API CH4 class or better) T/M oil Engine oil SAE10W-30(API CF4 class or better) Axle oil SAE 80W-90 Brake cooling oil SHELL DONAX TD Hydraulic oil ISO VG32/VG46/VG68...
Page 178: Fuel And Lubricants
14. FUEL AND LUBRICANTS 100D/120D/135D/160D-7 。 C (。 F) Capacityℓ(U.S.gal) Ambient temperature Service Kind of point fluid 10~12ton 13.5~16ton (-4) (14) (32) (50) (68) (86) (104) SAE 30 SAE 10W Engine oil 14.2 14.2 Engine oil (3.8) (3.8) SAE 10W-30...
Page 179: Specifications
8. SPECIFICATIONS 1. SPECIFICATION TABLE 100D/120D-7 C' C 160D7SP01 Model Unit 100D-7 120D-7 Capacity 10000 12000 Load center Weight(Unloaded) 14820 15965 Lifting height 3300 Free lift Lifting speed(Unload/Load) Fork mm/sec 510/440 510/430 Lowering speed(Unload/Load) mm/sec 460/510 L W T L,W,T...
Page 180 135D/160D-7 C' C 160D7SP01 Model Unit 135D-7 160D-7 Capacity 13500 16000 Load center Weight(Unloaded) 17240 18865 Lifting height 3300 Free lift Fork Lifting speed(Unload/Load) 450/360 450/350 mm/sec Lowering speed(Unload/Load) mm/sec 390/430 L,W,T L W T 1350 200 85 1350 200 90 C/C’...
Page 181: Main Control Valve
2 2 . SPECIFICATION FOR MAJOR COMPONENTS 100D/120D-7 ENGINE Item Specification Unit Model CUMMINS QSB5.9-C 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...
Page 182: 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 2.3 : 1 Type Full auto, power shift...
Page 183 135D/160D-7 ENGINE Item Specification Unit Model CUMMINS QSB5.9-C 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 102×120mm(4.02"×4.72") Piston displacement cc(cu in) 5883(359)
Page 184 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 2.3 : 1 Type Full auto, Power shift Gear shift(FR/RR)
Page 185: Tightening Torque
3. TIGHTENING TORQUE 100D/120D-7 Items Size kgf m lbf ft Engine mounting bolt, nut 100 15 723 109 Engine Radiator mounting bolt, nut M12 1.75 12.8 3.0 93 22 Hydraulic pump mounting bolt M12 1.75 9.0 0.5 65 3.6 Hydraulic MCV mounting bolt, nut M10 1.5...
Page 186: 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 187: Electrical System
2. ELECTRICAL SYSTEM Trouble symptom robable cause Remedy Lamps dimming even at maxi- Faulty wiring. Check for loose terminal and discon- mum engine speed. nected wire. Lamps flicker during engine Improper belt tension. Adjust belt tension. operation. Charge lamp does not light du Charge lamp defective.
Page 188: Torque Flow System
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 189 Trouble symptom robable cause Remedy 3.Low output power 1) Torque converter Insufficient hydraulic pressure : Low oil level. Check oil level and add oil Air sucked in. Check joints and pipes. If necessary, retighten joint or repla- ce packing. Oil filter clogging. Check and replace Oil pump worn.
Page 190 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 191 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 192: 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 193: 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 194: 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 195: 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 196: Radiator Cap
The fuel filter element cannot be inspected from the outside, so replace it periodically (every 3 months or 500 hours). 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 197 Move fan backwards and forwards by hand to check for looseness. Tighten mounting bolt with a spanner. Crack 160D7TA11 10-3...
Page 198: Drive System
2. DRIVE SYSTEM GEAR SHIFT LEVER Neutral starting Engine can be started only when the shifting lever is in neutral position. Shifting FWD/REV lever Forward Push the lever forward then forward solenoid valve operates and oil comes to forward clutch thus the truck will run forward.
Page 199 Inching pedal Adjust stopper bolt(1) so that pedal angle is "H"(voltage : 1 0.1V). - Pedal angle(H) : 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, 15mm(0.6in). 160D7TA05 10-5...
Page 200: 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 201: 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.

This manual is also suitable for:

120d 135d 160d

Hyundai 100D Manual

Quick Links

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Hyundai 100D

Summary of Contents for Hyundai 100D

This manual is also suitable for:

Table of Contents