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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2. OPERATING HAZARDS

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

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

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

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

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

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

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

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

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

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

11. Drop-offs - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6

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

CONTENTS

Table of Contents

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Summary of Contents for Hyundai 180D-7E

Page 1: Table Of Contents
CONTENTS 1. SAFETY HINTS 1. Daily inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 2.
Page 2 6. Switches - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-20 7.
Page 3 8. Electrical system- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-45 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 E E C REGULATION APPROVED · Noise level (2000/14/EC and EN 12053) are as followings. Model (EU only) 180D-7E 109 dB 77 dB · The value of vibrations transmitted by the operator's seat are lower than standard value of (2002/44/EC)
Page 9: Safety Labels
SAFETY LABELS 1. LOCATION Always keep these labels clean. If they are lost or damaged, attach them again or replace them with a new label. 16,17,18,19 28,30 29,30 DRIVE RH S/W "VIEW" (RADIATOR TOP) VIEW A-A CABIN INSIDE - RH CABIN INSIDE - LH 180D7EOM101 Logo...
Page 10 2. DESCRIPTION There are several specific warning labels on this machine please become familiarized with all warning labels. Replace any safety label that is damaged, or missing. WARNING-MAST(ltem 2) This warning label is positioned on the both side of the mast. Never stand or work under the raised forks even if the hydraulic safety lock lever is applied.
Page 11 HAND CAUTION (Item 7) This warning label is positioned on the top side of mast. It warns of the danger of injury from movement between rails, chains, sheaves, fork carriage, and other parts of the mast assembly. Do not climb on or reach into the mast.
Page 12 SAFETY INSTRUCTION (Item 13) Truck for USA or equipped with *OPSS. This warning label is positioned on the inside of cabin door if the truck is for USA or SAFETY INSTRUCTIONS equipped with *OPSS. This forklift equipped with an operator existence sensingsing system per ASME/ISO 3691 Power travel movement of the truck shall be possible only if the This forklift is equipped with an operator...
Page 13 OPERATOR SAFETY (item 15) This warning label is positioned on the front outside of overhead guard stay-LH. ① Refer to operator's manual in detail. ② Always buckle up the seat belt for safety operation. ③ When the operator get off the machine, always pull the parking brake lever so that the machine can keep with stopping condition.
Page 14: 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 15: 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 16: Do's And Dont's
2. DO'S AND DON'TS Do watch for pedestrians. D35AOM03 Do wear safety equipment when required. D35AOM05 Don't mix drugs or alcohol with your job. D35AOM02 Don't block safety or emergency equipment. 160D7OM04 Don't smoke in NO SMOKING areas or when refueling. D35AOM06...
Page 17 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 18: Seat Belts
3. SEAT BELTS Always buckle up for the truck equipped with safety belt. 160D7OM09 Seat belts can reduce injuries. 160D7OM11...
Page 19: No Riders
4. NO RIDERS The operator is the only one who should be on a truck. 160D7EOM12 Never transport personnel on the forks of a lift truck. 160D7EOM14...
Page 20: Pedestrians
5. PEDESTRIANS Watch where you are going. Look in the direction of travel. Pedestrians may use the same roadway you do. Sound your horn at all intersections or blind spots. 160D7EOM05 Watch for people in your work area even if your truck has warning lights or alarms.
Page 21: Operator Protection
6. OPERATOR PROTECTION Stay inside the cabin. Always keep your body within the confines of the truck. Do not operate truck without cabin or overhead guard, unless condition prevent use of it. 160D7EOM16...
Page 22: Fork Safety
7. FORK SAFETY Never allow anyone to walk under raised forks. D255OM17A There is special equipment to raise people for overhead work. DO NOT USE LIFT TRUCKS. 160D7EOM14 Always lower the load slowly. Raise and lower with mast vertical or tilted slightly back(Never forward).
Page 23: Pinch Points
8. PINCH POINTS Keep hands, feet and legs out of the mast. D255OM61 Don't use the mast as a ladder. 160D7EOM62 Never try to repair the mast, carriage, chain, or attachment by yourself. Always get a trained mechanic. 160D7EOM63...
Page 24: Travel
9. TRAVEL Travel with the load near the floor/ground, with mast tilted back to cradle the load whenever possible. Never lift or lower the load when the truck is in motion. 160D7EOM18 When handling bulky loads that restrict your vision operate your truck in reverse to improve visibility.
Page 25: Grades, Ramps, Slopes And Inclines
10. GRADES, RAMPS, SLOPES AND INCLINES Never turn on a grade, either loaded or unloaded. Unloaded-Forks downgrade 160D7EOM30 Loaded - Forks upgrade 160D7EOM33 1-11...
Page 26: 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 27 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 28: 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 29: Parking
13. PARKING Never park on a grade. 160D7EOM41 Always come to a complete stop before leaving truck. Be sure travel control is in NEUTRAL. 160D7EOM42 Lower forks fully to floor and tilt forward. 160D7EOM44 Set parking brake. Position 1 : OFF(Release) Position 2 : ON(Lock) Turn key to OFF position.
Page 30: Refueling
14. REFUELING Before adding oil, check around truck for oil leakage. 160D7EOM47 Keep away from fire when adding oil or during operation. 160D7OM48 After adding oil, wipe off any oil spilled on truck. 160D7EOM49 1-16...
Page 31: Step
15. STEP When getting on or off the truck, use the step provided. 160D7EOM50 Do not jump up or down from the truck. 160D7EOM52 1-17...
Page 32: Operator's Safety Rules
16. OPERATOR'S SAFETY RULES All operational functions require that the operator be seated in the operator's seat. Always buckle up if a seat belt is provided. 160D7EOM18 Parking brake must be locked in the PARK POSITION before exiting from the vehicle. 1.
Page 33: Operating Hazards
2. OPERATING HAZARDS 1. LOOSE LOADS Loose or unbalanced loads are dangerous. Observe these precautions. Never carry loose or uneven material. 160D7EOM53 Center wide loads. 160D7EOM55 Stack and band loose material. D35AOM41 Avoid sudden braking or starting When the truck is loaded, do not drive at maximum speed.
Page 34: 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 35: 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 36: 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 37: 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 38: Lifting Loads
10. LIFTING LOADS Never permit any persons to stand or pass under lifted load. 160D7EOM58 Never use wire rope to lift a load. 160D7EOM60 11. 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.
Page 39: Know Your Truck
3. KNOW YOUR TRUCK 1. GENERAL LOCATIONS 180D-7E 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...
Page 40: 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 41 OPERATOR SAFETY WARNING DECAL 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. Safety and warning decals.
Page 42: 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 CD/MP3 palyer...
Page 43: 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 44 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 45 Direction pilot lamp This lamp flashes when the signal indicator lever is moved. Work lamp pilot lamp (front / rear) This lamp lights ON when cabin work lamp switch is pressed. Head light pilot lamp This lamp comes ON when the main light switch is operated to 2nd step.
Page 46 This lamp lights ON and the T/M message display shows the error codes when an error occurs in the transmission. Immediately pull the truck to a convenient stop. Stop the engine. Investigate the cause. Consult a HYUNDAI dealer to investigate the cause. Do not operate until the cause has been corrected.
Page 47 (12) Air cleaner warning lamp This lamp operates by the vacuum caused inside when the filter of air cleaner is clogged. Check the filter and clean or replace it when the lamp is ON. (13) Battery charging warning lamp This lamp is ON after key switch is turned ON. Check the battery charging circuit when this lamp comes ON during engine operation.
Page 48 (17) Engine coolant temperature warning lamp This lamp is turned ON when the temperature of cooling water is over the normal temperature(104 C, 219 F). Check the cooling system when the lamp is ON. (18) Transmission oil temperature warning lamp This lamp informs the operator that transmission oil is above the specified temperature.
Page 49 CLUSTER BUTTON Each button has the following function. Buzzer stop button Next button MENU button Buzzer stop button This switch is used to stop the buzzer sound. Stop the buzzer when the switch is pressed. Menu and next button This switches are used to choose the model or display the engine error on the LCD.
Page 50 LCD has the functions to display start mode, standby mode, cruise function, model select and engine error. Display Name Description Display initialization state with HYUNDAI logo and Start mode program version. Standby mode Displays on the idle state. Displays rpm, odometer and hourmeter Odometer is on, is activated.
Page 51 Display Name Description On model select mode, displays like this image. Model select Refer to the page 3-11. In case of below 4 engine errors displays like this Engine error display image. Refer to the page 3-11. In case of over 4 engine errors displays like this image.
Page 52: 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 53 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 54 DISPLAY DURING AEB-MODE Symbol Meaning Remarks AEB-starter is plugged at the diagnostic plug AEB-Starter-button is pressed K1..K3 Calibrating clutch K1...K3, KV or KV, KR KR resp. _and Kx Wait for start, initialization of clutch Kx, x : 1, 2, 3, V, R and Kx Fast fill time determination of clutch Kx =and Kx...
Page 55 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 56: Switches
6. SWITCHES Cruise set-resume switch Cover(LH) Cruise switch Fuel heater switch Main light switch Work lamp switch Hazard switch Lock lever Rear wiper/washer switch Aircon switch STOP Seat heat switch DOWN Parking brake switch Control switch Auto/Manual select switch DETAIL A Inching switch Inc/Dec switch Cabin tilt switch location...
Page 57 HAZARD SWITCH Use for parking, or loading truck. If the switch is left ON for a long time, the battery may be discharged. INCHING SWITCH If this switch is pressed, inching operation is applied to inching pedal. Also, inching lamp on the cluster is illuminated. PARKING BRAKE SWITCH If this switch is pressed, the parking brake is applied and the gauge panel warning lamp will comes ON.
Page 58 REAR WIPER AND WASHER SWITCH This switch is used to operate the rear wiper and washer by two steps. First step : The rear wiper operates. Second step : The washer liquid is sprayed and the rear wiper is operated only while pressing. If release the switch, return to the f i r s t s t e p position.
Page 59: Horn Button
HORN BUTTON If you press the button on the top of the multifunction switch and the Horn button center of the steering wheel, the horn will sound. CAB LAMP SWITCH This switch turns ON the cab room lamp. MULTI FUNCTION SWITCH Front wiper and washer switch When the switch is in J position, the wiper moves intermittently.
Page 60 CRUISE SET/RESUME SWITCH Auto cruise function is used to travel at constant engine speed with RESUME a desired engine rpm. CRUISE This function is activated only when the CRUISE SWITCH is turned ON. If you want to travel the truck at constant speed, you raise the engine rpm and then press the CRUISE SET switch.
Page 61: Control Device
7. CONTROL DEVICE Lift lever Tilt lever Steering wheel 3-spool lever(opt) Gear selector lever 4-spool lever(opt) Inching pedal 5-spool lever(opt) Brake pedal Accelerator pedal LIFT LEVER LIFT PULL the lever BACK to LIFT the forks. Lower LOWER PUSH the lever FORWARD to LOWER the load. Lift HOLDING When the lever is released, the lifting or lowering action stops.
Page 62 GEAR SELECTOR LEVER This lever is used for gear selection, forward 3 stages and reverse 3 stages. If you push the gear selector lever, the truck moves forward, but pulling the gear selector lever, the truck moves backward. If you turn the gear selector lever forward, the truck increases the speed, but if you turn the gear selector lever backward, the truck reduces the speed.
Page 63 STEERING WHEEL LEVER By pulling down the lever, the wheel is adjustable to tilt. By pulling up the lever, the wheel is adjustable to telescope. 3-25...
Page 64: Air Conditioner And Heater
8. AIR CONDITIONER AND HEATER Air conditioner and heater are equipped for pleasant operation against outside temperature and defrost on window glass. Fan speed control switch Inlet change over switch Air position control switch Temperature control switch Air conditioner switch 3-26...
Page 65: Fan Speed Control Switch
FAN SPEED CONTROL SWITCH It is possible to control the fan speed to four steps. AIR POSITION CONTROL SWITCH This switch regulates the air position. Front Front & rear Rear Front & defrost Defrost TEMPERATURE CONTROL SWITCH This switch regulates the temperature of air. BLUE Right side(red zone) : Heat up air temperature Left side(blue zone) : Cool down air temperature...
Page 66: Others
9. OTHERS Front Engine control unit(ECU) Radio and CD/MP3 player Rear Transmission control unit(TCU) Monitor(opt) Handsfree(opt) Cigar lighter Fuse box Seat 3-28...
Page 67: 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 backward. Upward/Downward adjustment Push or pull the height adjust lever (B) to adjust seat upward or downward.
Page 68 FUSE BOX The fuses protect the electrical parts and wiring START KEY from burning out. FUSE HOLDER The fuse box cover indicates the capacity of each TCU(B+) fuse and circuit it protects. TURN LAMP HORN(B+) Replace a fuse with another of the same capacity.
Page 69: Front Panel Presentation
RADIO AND MP3 PLAYER(-#0037) CD inserter FRONT PANEL PRESENTATION --- ----------- Power and volume switch ------------ Preset memory button 1 REW ----------- Fast rewind (CD) PWR ----------- Press to power on/off VOL ------------Turn right/left to adjust the volume ------------ Preset memory button 2 ----------- Fast forward (CD) ------------AM/FM button (radio) ------------ Preset memory button 3...
Page 70 RADIO Power and volume switch Power ON/OFF This switch is used to turn the audio ON or OFF. Volume This switch turned to right or left, the sound is increased or FM/AM button You can broadcasting on AM or FM band by pressing this band selection button.
Page 71 Preset memory button Manually storing stations in a preset Six stations per band can be stored and recalled using the preset keys (1 to 6). Tune in to the desired station. Press the desired preset key (1 to 6) for more than 0.8 seconds to store the current tuned station.
Page 72 CD/MP3 PLAYER CD playback button It is possible to change CD playback during broadcasting. If there was no CD on audio, "NO DISC" displays on LCD during 5 seconds. Track button CD player Short press : Select the next/previous track Long press : Select the fast forward or rewind MP3 player Memory file search up/down...
Page 73 Repeat track button(CD) Press this button to activate repeat current track playback. The LCD displays "RPT". It is canceled press one more this button. Mark button(MP3) Memory Press over 0.8 second, the current file memorized with a beep (max 100 tune memory). The LCD displays "M"...
Page 74: Monitor(Option)
MONITOR(OPTION) Adjusting the angle Upwards and downwards up to 7 total 14 . Swivels left and right up to 15 total 30 . Power button Enter button Left selection button Right selection button Camera / ESC button Power button To turn the power off or on. To switch the monitor on or off, press and hold the power button for two second.
Page 75 Name Description ESL(Engine Starting Limit) screen The password must be 5~10 digits long. After input password, you must input Default password : '0000000000'(digit '0', 10 times) Menu selection screen Camera selection To enter camera screen, press button. To return to menu selection screen, press button.
Page 76 Name Description Changing password The password must be 5~10 digits long. After input password, you must input Display set up screen LCD brightness To adjust to display brightness, press to decrease or increase. Language selection 3-57...
Page 77: 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 78: 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 79: 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 80: 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 81: 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 82: 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 83: 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 84: 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 85: Check Battery
CHECK FAN BELT TENSION Cooling fan belt tensioner Maintenance check With the engine turned off, check that neither the top nor bottom tensioner arm stop is touching the cast boss on the tensioner body. If either of the stops is touching a boss, the 7807AMI50 alternator belt must be replaced.
Page 86: Check Hydraulic Oil Level
HECK HYDRAULIC OIL LEVEL Rest fork on ground and stop engine. Check the oil level from the level gauge of hydraulic oil tank. Upper limit In accordance with the mast equipped, the oil level differs. Lower limit Gauge V - mast TS - mast (U.S.gal) Lower limit...
Page 87 CHECK PEDALS Check for any catching or abnormal heaviness when depressing the pedals. Inching pedal Free play : Max 1 Interlock stroke with brake pedal : 7 Brake pedal Free play : Max 1...
Page 88: Seat Adjustment
4. 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. Forward/Backward adjustment (slide adjustment) Pull lever (A) to adjust seat forward or backward.
Page 89: 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 90: 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 91: Starting And Stopping The Engine
7 7 . STARTING AND STOPPING THE ENGINE CHECK INDICATOR LIGHTS Check if parking brake switch is ON. Gear selector lever Check if gear selector lever is in neutral position. Parking brake switch Turn the key to the ON position, and check following.
Page 92 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 93 INSPECTION AFTER ENGINE START Inspect and confirm the following after engine starts. Is the level gauge of hydraulic oil tank in the normal level? Are there leakages of oil or water? Are all the warning lamps OFF? Check the following after warming up operation. Is the indicator of engine coolant temperature gauge (1) in the operating range? Is the indicator of transmission oil temperature...
Page 94 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 95: 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 96: 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 oil temperature is below 25 C (77 F ). The temperature must be raised to at least 25 C (77 F ) before starting work.
Page 97: 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 98 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. During traveling in forward or reverse direction, a sudden Reverse change of direction can cause to drop a load and damage to the machine.
Page 99: Traveling Of The Truck
10. TRAVELING OF THE TRUCK BASIC OPERATION Tilt back fully Traveling posture Lift the forks so that the forks are placed 15- 20cm(6~8in) above the ground and tilt back the mast fully. 160D7EOP10 Traveling operation When warm-up operation is completed after the Gear selector lever engine is started, move the truck according to Parking brake switch...
Page 100 ※ When traveling at high speed, do not abruptly decelerate by using the trans- mission lever, to slow down instead press the brake pedal. ※ When changing direction, check beforehand there is no obstacle in the direction you will be headed. ※...
Page 101 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. Press the parking brake switch. 180D7EOP14 Lower the forks to the ground. Low idling for 5 minutes 160D7EOP07 5-20...
Page 102 Stopping engine If the engine is abruptly stopped before it has Gear selector lever cooled down, its service life may be Parking brake switch shortened. Avoid sudden stop except an emergency. When the engine is overheated, do not stop immediately. Run the engine at a mid range speed to allow it to cool down, then stop it.
Page 103: 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 104 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 105: 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 106 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 107 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 108 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 109 STACKING To put a load on a stack Approach 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 110 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 111: Shut Down Procedure
1 1 3. SHUT DOWN PROCEDURE Always leave your lift truck in a safe condition. WHEN YOU LEAVE YOUR TRUCK, OR PARK IT, FOLLOW THESE SAFELY RULES Park in a safe area away from normal traffic. Never park on a grade or a slope. Never park in areas that block emergency routes or equipment, access to fire aisles, or stairways and fire equipment.
Page 112: 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 113: Transport
15. TRANSPORT PRECAUTIONS FOR LOADING AND UNLOADING Contact your HYUNDAI forklift distributor for advice regarding transportation of the truck. When loading or unloading the truck on or from a transporter, using loading ramp, the following precautions must always be observed.
Page 114: Loading And Unloading By Crane
16. LOADING AND UNLOADING BY CRANE Check the specification of the truck when you are going to hoist the truck. Use long wire rope and stay to keep the distance Stay Wire rope with the machine as it should avoid touching with the truck body.
Page 115: 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 116 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 117: 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 118 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 119: Introduction
Specifications for selected components, fuel, lubricants, critical bolt torques, refill capacities, and settings for the truck and found in section 9. If you have needed for more information on the care and repair of your truck, see your HYUNDAI dealer.
Page 120: 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 121 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 122 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 123: Instructions Before Maintenance
3. INSTRUCTIONS BEFORE MAINTENANCE INTERVAL OF MAINTENANCE You may inspect and service the machine by the period as described at based on service meter of LCD. Shorten the interval of inspect and service depending on site condition.(Such as dusty area, quarry, sea shore and etc.) Practice the entire related details at the same time when the service interval is doubled.
Page 124: 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 125 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 126: Planned Maintenance Intervals
4. PLANNED MAINTENANCE INTERVALS MAJOR COMPONENTS LOCATION 160D7EOM21 Mast Transmission 17 Counterweight Lift cylinder 10 Torque converter 18 Radiator Steering unit 11 Engine 19 Seat Tilt cylinder 12 Steering cylinder 20 Cabin Main control valve 13 Hydraulic pump 21 Steering wheel Fork 14 Steering axle 22 Muffler...
Page 127 MAINTENANCE CHECK LIST EVERY 10 HOURS SERVICE Check items Service Remarks Visual inspection ·Truck for obvious damage and leaks. 7-14 Check, Repair or Replace ·Warning plates and decals. 7-14 Check, Replace ·Condition of tires and wheels. Air pressure. 7-16 Check, Refill or Replace ·Lift chain and fastener.
Page 128: Every 250 Hours Service
INITIAL 100 HOURS SERVICE Check items Service Remarks Differential gear oil Change 7-41 Transmission oil and filter Replace 7-38 Brake cooling oil Change 7-42 EVERY 250 HOURS SERVICE Check items Service Remarks Differential gear oil Check, Refill 7-41 Lubrication ·Lift chain Check, Lubricate 7-60 ·Mast roller and pin...
Page 129 Replace 7-33 Conventional hydraulic oil EVERY 5000 HOURS SERVICE Check items Service Remarks Replace 7-33 Hydraulic oil(* Hyundai genuine long life hydraulic oil WHEN REQUIRED Check items Service Remarks Fuel system 7-27 ·Fuel tank Drain or Clean 7-29 ·Water separator...
Page 130: Maintenance Locations
5 5 . MAINTENANCE CHART MAINTENANCE LOCATIONS 180D7EMA011 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 131: Maintenance Chart
Check, Clean Hydraulic oil Change 5000 Hours Hydraulic oil Change Conventional hydraulic oil Hyundai genuine long life hydraulic oil ※ Oil symbol Refer to the recommended lubricants for specification. DF : Diesel fuel HO : Hydraulic oil EO : Engine oil...
Page 132: 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 133 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 (mm) Height difference (mm) equal or below 1500...
Page 134: Wheel And Tires
WHEEL AND TIRES Check the condition of the drive and steering wheels and tires. Remove objects that are embedded in the tread. Inspect the tires for excessive wear and breaks or chunking out. Check all wheel lug nuts or bolts to be sure none are loose or missing.
Page 135 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. Cover(LH) Locate the truck on the plain and stable floor. Apply parking brake before servicing.
Page 136 Do not operate the tilt control switch or any control parts while servicing under the tilted cabin. It can cause severe injury or death. WARN OPERATE 160D7EMI64 The angle of fully tilted cabin is 65 。。 and the safety lock function operates within the tilting angle of 20 。...
Page 137: Service Instruction
7. SERVICE INSTRUCTION CHECK ENGINE OIL LEVEL Engine oil fill 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 138 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. 180D7EMI10 Clean and inspect the oil drain plug threads and the seal surface.
Page 139 (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. 180D7EMI05 CHECK COOLANT LEVEL Check the coolant level at reservoir tank.
Page 140 FLUSHING AND REFILLING OF RADIATOR Change coolant Avoid prolonged and repeated skin contact with used antifreeze. Such prolonged repeated contact can cause skin disorders or other bodily injury. Avoid excessive contact-wash thoroughly after contact. Keep out of reach of children. 160D7EMI31 Protect the environment : Handling and disposal of used antifreeze can be subject to...
Page 141 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 142 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 143: 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 144 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 145: 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 misalignment is three degrees. This measurement can be taken with a straightedge and an inclinometer. Install the belt. 7807AMI54 CLEANING OF AIR CLEANER Clamp...
Page 146: 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 147 REFILTER Inspect or drain the collection bowl of water daily and replace the element every 500hours. Drain water Bowl Open bowl drain valve to evacuate water. Drain valve Open Close drain valve. Close 2907A6MI20 eplace element Drain the unit of fuel. Follow "Drain water" instructions above.
Page 148: 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 149 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 150: 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. 180D7EMI16 HYDRAULIC OIL CHECK Level gauge Lower the forks on the ground at a flat location as in the illustration.
Page 151: Change The Hydraulic Oil
CHANGE THE HYDRAULIC OIL Air breather Lower the forks on the ground and extend the tilt cylinder to the maximum. Loosen the cap and relieve the pressure in the tank. Prepare a suitable drain pan. To drain the oil loosen the drain plug. After draining oil, tighten the drain plug.
Page 152 REPLACEMENT OF ELEMENT IN HYDRAULIC TANK BREATHER Loosen the cap and relieve the pressure in the tank. Air breather Loosen the screw and remove the cover. Pull out the filter. Air breather Replace the filter with new one. Reassemble by reverse order of disassembly. Tightening torque of the bolts : Element 2.7~4.1kgf m (19.5~29.7lbf ft)
Page 153: 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) Pressure Size...
Page 154: 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 155 Loosen slightly all wheel mounting. Tools : Socket 22mm 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 156: 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 157 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 158 CLEANING TRANSMISSION AIR BREATHER Air breather Remove dust or debris around the air breather. Remove the air breather and wash it with cleaning oil. 180D7EMA45 CHECK AND SUPPLYING AXLE OIL Move the machine to flat ground. Air breather Open the axle air breather to relieve internal air pressure.
Page 159 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 160 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 161 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 162 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 163: 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 164: Air Conditioner And Heater
9. AIR CONDITIONER AND HEATER CLEANING AND REPLACING FILTER Recircular Always stop the engine before servicing. plenum assy Open the door, loosen the wing bolt and remove the recircular plenum assembly. 160D7EMI58 Clean the recircular plenum using a pressurized air(Below 2kgf/cm , 28psi).
Page 165: Replacement And Check
10. REPLACEMENT AND CHECK 10. REPLACEMENT AND CHECK 1) 1) WIRING, GAUGES WIRING, GAUGES Check regularly and repair the 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 166: 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 167 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 168: 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 parking brake. Air breather Oil level check Open inspection plate, and oil level can be checked using dipstick.
Page 169: Hydraulic Tank
HYDRAULIC TANK Hydraulic oil change Park the truck in a level place and lower the forks. Then stop the engine and apply the parking brake. Change oil after removing drain plug on tank bottom. Drain plug Drain pan 180D7EOM28 Strainer Cleaning OSHA-approved eye protection rated for 200kPa(30psi) is required for air cleaning operation.
Page 170: 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 171 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 172: Fuses Replacement
FUSES REPLACEMENT Fuse box #1 No. Capacity Color Related electrical component START KEY Start key FUSE TCU(B HOLDER TCU(B+) Turn lamp OPSS(B Blue ECU(B TURN LAMP HORN(B+) Blue ECU(B CD/MP3(B OPSS(B+) MONITOR(B+) Room lamp Cluster(B ECU(B+) CABIN TILT Blue Cabin tilt Monitor(B Horn(B ECU(B+)
Page 173 LAMP BULBS REPLACEMENT Lamp Spec(24V) Head lamp(up) Head lamp(down) Turn signal lamp Clearance lamp Stop lamp Backup lamp License lamp (option) 3.4W 160D7EOM69 Beacon lamp (option) Strobe type Rear work lamp After checking that the fuse is not blown and that there is no disconnection in the wiring harness, replace the lamp bulb.
Page 174 Service brakes and inching pedal With the direction control in NEUTRAL and the engine running, push the service 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 175 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 176 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 177 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 178: 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 179 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 180 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 181: 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 182: 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 183: Recommendation Table For Lubricants
SAE 10W-30/15W-40(API CH4 class or better) T/M oil Engine oil SAE10W-30(API CF4 class or better) Axle oil/Brake cooling oil SAE 80W-90/Donax TD Hydraulic oil ISO VG32/VG46/VG68, Hyundai genuine long life hydraulic oil Grease Lithium base grease NLGI No.2 Fuel ASTM D975-No.2 Coolant Mixture of 50% ethylene glycol base antifreeze and 50% water ㆍSAE : Society of Automotive Engineers...
Page 184: Fuel And Lubricants
14. FUEL AND LUBRICANTS 。 C (。 F) Ambient temperature Service Kind of Capacityℓ(U.S.gal) point fluid (-4) (14) (32) (50) (68) (86) (104) SAE 30 SAE 10W Engine oil Engine oil (5.3) SAE 10W-30 SAE 15W-40 SAE 10W-30 Torque converter Engine oil (7.1) transmission...
Page 185: Specification
8. SPECIFICATIONS 1. SPECIFICATION TABLE 180D-7E C' C 160D7ESP01 Model Unit 180D-7E Capacity 18000 Load center Weight(Unloaded) 25689 Lifting height 3320 Free lift Fork Lifting speed (Unload/Load) mm/sec 420/370 Lowering speed (Unload/Load) 300/420 mm/sec L,W,T 2450 250 100 Tilt angle (forward/backward) C/C’...
Page 186: Main Control Valve
2 2 . SPECIFICATION FOR MAJOR COMPONENTS 180D-7E ENGINE Item Specification Unit Model CUMMINS QSC Type 4 cycle turbocharged and inter cooled 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...
Page 187: Steering Unit
TEERING UNIT Item Unit Specification Load sensing/Non load reaction/Dynamic signal Type Capacity cc/rev Rated flow POWER TRAIN DEVICES Item Specification Model W340, 1.773/271 (ZF SACH) Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 1.773 : 1 Type Full auto, power shift Gear shift(FR/RR) Transmission...
Page 188: 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 93 ± 22 Hydraulic pump mounting bolt M12 × 1.75 12.8 ±...
Page 189: 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 190: 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 191 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 192 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 193 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 194 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 195: 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 196: 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 197: 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 198: 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 199: 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 200 Move fan backwards and forwards by hand to check for looseness. Tighten mounting bolt with a spanner. Crack 160D7TA11 10-3...
Page 201: 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 202 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, 22mm(0.9in). 160D7ETA05 10-5...
Page 203: 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 204: Steering System
4. STEERING SYSTEM STEERING WHEEL 30~60mm Set rear wheels facing straight forward, (1.2~2.4 in) then turn steering wheel to left and right. Measure range of steering wheel movement before rear wheel starts to move. Range should be 30 - 60mm at rim of steering wheel.

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