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FOREWORD
FOREWORD
A message to hyundai lift truck operators ----------------------------------------------------------------------- 0-1
Introduction ------------------------------------------------------------------------------------------------------------------------ 0-2
How to use this manual ---------------------------------------------------------------------------------------------------- 0-3
EC regulation approved ----------------------------------------------------------------------------------------------------- 0-5
Safety labels ---------------------------------------------------------------------------------------------------------------------- 0-6
Guide (Direction, Serial number, Symbols) -------------------------------------------------------------------- 0-16
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
17. Side shift ------------------------------------------------------------------------------------------------------------------------- 1-19
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
CONTENTS
CONTENTS
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Table of Contents
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Summarization of Contents
Introduction to Hyundai Lift Truck Manual
Routine Servicing and Maintenance
Importance of regular maintenance for safety, economy, and utilization.
Operator Daily Inspection
Procedure for operator's pre-drive safety and operating checks.
Planned Maintenance
Recommended periodic maintenance by trained mechanics for safety and efficiency.
Safety Labels Overview
1. Location of Safety Labels
Overview of where various safety labels are placed on the truck.
Description of Warning Labels
Mast Warning Label
Warning about dangers under raised forks and essential support for the carriage.
Temperature Warning Label
Warning about coolant level and maintenance chart for temperature checks.
Radiator Warning Label
Warning against opening surge tank filler cap due to hot water scalding risk.
Description of Warning Labels (Continued)
Radiator Fan Warning Label
Warning of danger from spinning fan blades and keeping body parts away.
Hand Caution Label
Warning of injury from mast assembly movement, prohibiting climbing or reaching into mast.
Tire Pressure Warning Label
Importance of checking tire pressure as per maintenance chart and referring to specific pages.
Description of Warning Labels (Continued)
Start Procedure Warning Label
Step-by-step instructions for starting the engine, including fuel transfer pump and grid heater operation.
Start Warning Label
Warnings before leaving operator seat and cautions before starting or operating the truck.
Description of Warning Labels (Continued)
Safety Instruction Label (OPSS)
Instructions for trucks equipped with Operator Presence Sensing System (OPSS).
ECU/TCU Caution Label
Caution to separate ECU and TCU connectors before welding.
Engine Wash Warning Label
Warning not to wash the engine room.
Description of Warning Labels (Continued)
Operator Safety Label
General operator safety rules, including seat belt, parking brake, and tip-over precautions.
Cabin Tilt (Up/Down) Label
Instructions for tilting the cab for service and preventing unexpected lowering.
Description of Warning Labels (Continued)
Tilt Cabin Warning Label
Warning about safe tilting procedure and closing switch cover after cabin tilting.
Tilt Warning Label
Warning to close switch cover after cabin tilting to avoid tripping.
Solid Tire Warning Label
Caution against excessive driving with solid tires and not driving on public roads.
Noise Level Label
Information on noise level measurement.
Fire Extinguisher Label
Instruction to read and understand the safety decal on the fire extinguisher.
Description of Warning Labels (Continued)
Diesel Fuel Warning Label
Warning to fill only diesel fuel and not gasoline.
Hydraulic Oil Warning Label
Warning to fill only hydraulic oil and not diesel fuel.
Accumulator Warning Label
Warning about high-pressure nitrogen gas in accumulator and necessary safety precautions.
Description of Warning Labels (Continued)
DEF / AdBlue® Warning Label
Warning to fill only DEF/AdBlue® and never use diesel oil.
Air Compressor-Cabin Warning Label
Precautions for using the air compressor, including parking, engine operation, and electrical devices.
Air Compressor-Tank Warning Label
Warning not to touch the cylinder head during operation due to potential burn.
Description of Warning Labels (Continued)
Brake Cooling Oil Warning Label
Warning to use only specified brake cooling oil and never others.
Hammer Warning Label
Information about the rear window as an alternate exit and how to remove it.
SCR Warning Label
Warning not to touch the aftertreatment device due to heat and potential burns.
Guide to Truck Operation
1. Direction of Truck Travel
Explanation of truck's forward, backward, right, and left directions.
2. Serial Number Location
Information on where to find truck and engine serial numbers for ordering parts.
3. Explanation of Symbols
Explanation of symbols indicating important safety hints or useful operator information.
1. Safety Hints: Daily Inspection
Daily Inspection Procedure
Procedure for inspecting the truck at the beginning of each shift for damage and maintenance issues.
11. Tip Over Hazards
Lateral Tip Over Causes
Causes of lateral tip over like speed, turn sharpness, load, and incline.
Longitudinal Tip Over Causes
Causes of longitudinal tip over like overloading, load elevation, and driving on slopes.
11. Tip Over Hazards (Continued)
Actions During a Tip Over
Instructions on what to do if the truck tips over, emphasizing not to jump and to brace oneself.
16. Operator Safety Rules
Operator Seating and Seat Belt Use
Requirement for operator to be seated for all functions and buckle seat belt.
Parking Brake Lock Requirement
Rule to lock parking brake before exiting and keeping it locked unless operator is in normal position.
OPSS Regulations
Traction safety and parking brake warning functions related to the Operator Existence Sensing System.
2. Operating Hazards: Loose Loads
Hazards of Loose Loads
Hazards of loose or unbalanced loads and precautions like centering wide loads and banding loose material.
2. Operating Hazards: Load Handling
Long and Wide Loads Safety
Need for more room, slowing down, and being alert to load end-swing when handling long/wide loads.
Rear Swing Hazard
Warning to ensure rear end of truck does not swing into obstacles and to watch for pedestrians when turning.
2. Operating Hazards: Clearance and Turns
Low Overhead Clearance Hazard
Importance of knowing truck height and checking clearances to avoid tipping or spilling loads.
Fast Turns and High Loads Hazard
Warning to slow down before turning and that sharp turns with raised loads can cause tip over.
2. Operating Hazards: Stacking and Chains
Right Angle Stacking Precautions
Precautions for right angle stacking with raised loads, avoiding sharp turns and moving slowly.
Chain Slack Hazard
Hazards of slack chains causing hang-up and importance of raising forks before moving.
2. Operating Hazards: Pallets and Electrical Lines
Pallets and Skids Safety
Warning against using damaged pallets/skids and ensuring good condition of pallets.
Caution for Electrical Lines
Crucial safety information on minimum safe separation distances from electrical lines.
3. Know Your Truck: General Locations
1. General Locations of Components
Diagram and list of major components and their locations on the lift truck.
2. Name Plate and Safety Warning Decals
1) Name Plate Information
Details on truck model, type, serial number, attachment description, and capacity rating.
2. Name Plate and Safety Decals (Continued)
2) Operator Safety Warning Decals
Importance of safety decals for essential procedures and reminders, especially tip-over warnings.
3. Cab Devices Overview
1) Ergonomic Cab Design
Description of the ergonomically designed console box and suspension seat for operator comfort.
2) Electronic Monitor System
Functionality of the centralized electronic monitor system for truck status and safety warnings.
4. Cluster Gauge Functions
1) Cluster Structure
Components of the cluster: gauges, lamps, buttons, and LCD for operation warnings.
2) Gauges on the Cluster
Speed Meter Gauge
Display of truck speed in mph and km/h.
Fuel Gauge
Fuel level indicator and warning for refueling.
Engine Coolant Temperature Gauge
Coolant temperature indicator with normal and red ranges, and actions for overheating.
Transmission Oil Temperature Gauge
Transmission oil temperature indicator with normal and red ranges, and actions for overheating.
3) Warning Lamps on the Cluster (Continued)
Engine Oil Pressure Warning Lamp
Indicator for low oil pressure and immediate action required.
Air Cleaner Warning Lamp
Indicator for clogged air cleaner filter and cleaning procedure.
Battery Charging Warning Lamp
Indicator for battery charging circuit issues.
Fuel Low Level Warning Lamp
Indicator for low fuel level and refueling instruction.
Water in Fuel Warning Lamp
Indicator for water in fuel and procedure to drain it.
3) Warning Lamps on the Cluster (Continued)
Seat Belt Warning Lamp
Indicator for seat belt status, active for initial seconds after starting.
Engine Coolant Temperature Warning Lamp
Indicator for coolant temperature above normal and cooling system check.
Transmission Oil Temperature Warning Lamp
Indicator for transmission oil temperature above specified level and action for overheating.
Transmission Error Warning Lamp
Indicator for transmission errors shown on LCD, requiring immediate stop and investigation.
Brake Oil Temperature Warning Lamp
Indicator for high brake oil temperature and action to stop engine and check.
3) Warning Lamps on the Cluster (Continued)
SCR Cleaning Warning Lamp
Indicator for SCR cleaning needs and manual SCR cleaning activation.
3) Warning Lamps on the Cluster (Continued)
DEF Low Warning Lamp
Indicator for low diesel exhaust fluid level and instruction to add DEF.
Engine Stop Warning Lamp
Indicator for engine stop condition and immediate action required.
Fan Error Warning Lamp
Indicator for cooling fan error.
4) Pilot Lamps on the Cluster (Continued)
Head Light Pilot Lamp
Indicator for main light switch operation.
Preheater Pilot Lamp
Indicator for preheating status and when to start cranking the engine.
Inching Pilot Lamp
Indicator that lights up when the inching switch is pressed.
Fuel Warmer Pilot Lamp
Indicator for hydraulic fluid or engine coolant temperature conditions affecting fuel heating.
OPSS Pilot Lamp
Indicator for operator leaving the seat and related safety functions.
4) Pilot Lamps on the Cluster (Continued)
SCR Cleaning Inhibit Pilot Lamp
Indicator that inhibits automatic and manual SCR cleaning, especially in high-temperature environments.
HEST Pilot Lamp
Indicator for high exhaust temperatures during SCR cleaning, with safety warnings.
DEF Level Pilot Lamp
Indicator for DEF level and instruction to fill.
Expendables Replacement Pilot Lamp
Indicator for existing expendables needing replacement.
Cooling Fan Reverse Rotation Pilot Lamp
Indicator for cooling fan operating in reverse rotation.
5) LCD Display Functions
Main Screen Display
Overview of the main screen display and menu selection.
Camera Screen Display
Display of camera feed based on gear position or signal abnormality.
5) LCD Display Functions (Continued)
Main Menu Structure
Structure of the main menu: Equipment, Maintenance, and Display settings.
5) LCD Display Functions (Continued)
Equipment Settings
Steps to choose equipment, including model selection and password input.
5) LCD Display Functions (Continued)
Tilt Setting Adjustment
Procedure for setting tilt angle for mast and vehicle sensors.
Rear Wheel Angle Calibration
Calibrating rear wheel angle and setting display for approval.
5) LCD Display Functions (Continued)
Weight Sensor Settings
Setting cross-section, load weight adjustment, and overload warning buzzer.
5) LCD Display Functions (Continued)
Weight Display Setting
Selecting number of points for weight value display.
Overload Warning Buzzer Setting
Choosing buzzer setting for overload warnings.
5) LCD Display Functions (Continued)
ESL Setting for Ignition Control
Setting ON/OFF function for ignition and time limitation for starting.
5) LCD Display Functions (Continued)
Vehicle Max Speed Limit Setting
Setting the maximum speed limit for the truck.
AEB Setting and Calibration
Procedure for AEB setting and calibration, including brake pedal sensor calibration.
MCU/Cluster Information Display
Checking software version for MCU/Cluster/RMCU.
5) LCD Display Functions (Continued)
Cooling Fan Reverse Mode Settings
Setting manual and automatic modes for cooling fan reverse rotation.
5) LCD Display Functions (Continued)
Finger Tip Lever Position Settings
Ability to set maximum pull, push, and neutral values for levers.
5) LCD Display Functions (Continued)
Lever Deadzone Settings
Preventing value output errors due to tiny neutral lever state deviations.
5) LCD Display Functions (Continued)
Valve Setting for Coil Control
Setting current values for valve coils to adjust movements and speed.
5) LCD Display Functions (Continued)
Maintenance Options and Failure History
Maintenance options, including password input and failure history.
5) LCD Display Functions (Continued)
Delete Logged Fault History
Initializing the past logged fault history.
Maintenance Management
Managing expendable supplies and replacement cycles.
5) LCD Display Functions (Continued)
Signal Status Monitoring
Displaying information from various sensors.
User Password Change
Changing user password and setting it to five to ten digits.
5) LCD Display Functions (Continued)
Opening Communication with RMCU
Procedures for opening communication with RMCU and detecting GPS antenna.
5) LCD Display Functions (Continued)
LCD Adjustment Settings
Manual and automatic settings for LCD brightness and day/night time.
Time Setting
Setting the year, month, day, hour, minute, and AM/PM.
5) LCD Display Functions (Continued)
Unit Setting Options
Changing units for temperature, speed, weight, and pressure.
Language Setting Options
Setting the display language from multiple options.
A/S Phone Number Configuration
Changing contact information for customer service.
ESL Password Change Procedure
Changing the ESL password to five to ten digits.
5) LCD Display Functions (Continued)
Maintenance Management Details
Displaying maintenance information like replacement cycle and elapsed time.
5. Transmission Message Display
1) Transmission Message Display Function
Display features indicating speed, driving direction, and error codes.
Switch Functions Overview
Start Switch Operation
Positions (OFF, ON, START) and precautions for the start switch.
Hazard Switch (Option) Function
Use of hazard switch for parking or loading and battery discharge warning.
Inching Switch Function
Function of the inching switch for inching pedal operation and cluster illumination.
Parking Brake Switch Function
Function of the parking brake switch for lock/release and warning lamp activation.
Main Light Switch Operation
Operation of the main light switch for clearance lamps and headlights.
Switch Functions Overview (Continued)
Work Lamp Switch Operation
Operation of work lamps by two steps for front and rear.
Auto/Manual Changeover Switch Modes
Modes for autoshift function: manual, automatic 1st, and automatic 2nd.
Cabin Tilt Switch Operation
Operation of horn and cabin tilt switch for tilting and returning the cabin.
Hand Pump Lever Usage
Use of hand pump lever for tilting cabin clockwise or counterclockwise.
Switch Functions Overview (Continued)
Fuel Warmer Switch Function
Function of the fuel warmer switch for heating fuel.
Beacon Lamp Switch (Option)
Function of the beacon lamp switch for strobe light.
Inc/Decrement Switch Function
Adjusting engine low idle rpm using the increment/decrement switch.
Top Wiper and Washer Switch (Option)
Operation of wiper and washer on the top of the cab.
Horn Button Function
Function of the horn button on the multifunction switch and steering wheel.
Switch Functions Overview (Continued)
Cab Lamp Switch Function
Function of the cab lamp switch for turning on the cab room lamp.
Multi Function Switch Operations
Operation of front wiper/washer, dimmer switch, and turning signal switch.
Master Switch (Option) Function
Function of the master switch for shutting off the electrical system and battery connection.
Switch Functions Overview (Continued)
SCR Cleaning Switch Functions
Selection of SCR cleaning functions: inhibit, OFF, and manual positions.
Rear Wiper/Washer Switch Operation
Operation of wiper and washer on the rear of the cab.
Engine Mode Switch Options
Selection of operating modes: STANDARD for fuel efficiency and POWER for output.
Switch Functions Overview (Continued)
Air Compressor Switch (Option)
Function of the air compressor switch.
Seat Heat Switch (Option)
Function of the seat heat switch.
Cooling Fan Control Switch (Option)
Control of cooling fan with AUTO, OFF, and MANUAL positions.
Lever and Pedal Operations
Lift Lever Operation
Operation of lift lever for lifting, lowering, and holding forks, with speed control information.
Tilt Lever Operation
Operation of tilt lever for tilting mast forward, backward, and holding, with speed control information.
Side Shift Lever Operation
Operation of side shift lever for moving left or right.
Lever Operations (Continued)
Side Shift with Fork Positioner Lever
Operation of levers for fork positioner (synchronizer and independent types) for outward and inward movement.
Lever and Pedal Operations (Continued)
Gear Selector Lever Operation
Operation of gear selector lever for forward, neutral, and reverse, and speed control.
Steering Wheel Function
Steering function operated by steering wheel and movement direction.
Brake Pedal Function
Function of brake pedal for stopping the truck and precautions.
Accelerator Pedal Function
Function of accelerator pedal for controlling engine speed and low idling.
Inching Pedal Usage
Use of inching pedal for fine control of forward/reverse movement and precautions.
Lever and Pedal Adjustments
Steering Wheel Adjusting Lever
Adjusting steering wheel for tilt and telescope, and locking mechanism.
Engine Hood Operation
Procedure for opening the engine hood.
8. Air Conditioner and Heater System
Air Conditioner Button Operation
Operation of the air conditioner system and determination of cooling function.
8. Air Conditioner and Heater System (Continued)
Outlet Control Button Functions
Selection of five kinds of air flow: Face, Rear, Face/Rear, Face/Defrost, Defrost.
Temperature Control Knob
Regulation of air temperature for cooling (red zone) and heating (blue zone).
Air Inlet Control Button
Selection of inlet air: fresh air or cab circulation, with filter maintenance advice.
Fan Speed Control Knob
Control of fan speed automatically by temperature or manually.
9. Others: Component Functions
Cigar Lighter and 12V Socket Usage
Use of cigar lighter and 12V socket, with power limits and service socket precautions.
Transmission Control Unit (TCU) Function
Function of TCU in shifting speeds based on criteria like gear position, speed, and load.
Engine Control Module (ECM) Function
Role of ECM as the control center for the engine system.
Machine Control Unit (MCU) Function
Function of MCU in controlling lamps and buzzers based on signals from various components.
Audio System General Controls
Power and Volume Button
Power ON/OFF and volume control for the audio system.
Sound Function Selection
Adjusting sound modes (BASS, TREBLE, BAL, LOUD, EQ) and controlling levels.
Audio System General Controls (Continued)
Balance Control for Speakers
Adjusting left-right speaker balance and display of balance position.
Loud Control for Low Volume
Boosting bass and treble response at low volume levels.
Equalizer (EQ) Settings
Selecting equalizer curves for different music types (POP, ROCK, CLASSIC, JAZZ).
Radio Functions
AM/FM/LW Band Selector
Changing radio bands (FM1, FM2, FM3, AM, LW) and availability of LW band.
Up/Down Tuning for Radio Stations
Automatic and manual radio station tuning procedures.
Station Pre-set Button Usage
Recalling favorite pre-set radio stations and storing new ones.
Radio Functions (Continued)
Pre-set Scan (PS) / Best Station Memory (BSM)
Scanning and storing pre-set radio stations, and activating BSM tuning.
USB Player Functionality
Connecting a USB device to listen to MP3 files and display of file information.
AUX Functionality
Connecting external audio devices via AUX cable and changing modes.
USB Player Functions (Continued)
File Selection and Cue/Review
Selecting files up/down and using cue/review functions for audible search.
MP3 Directory and File Searching
Selecting directories and files, with examples of search methods.
USB Player Functions (Continued)
ID3 v2 Display Information
Changing display information for MP3 files, showing directory, album, or file name.
File Scan (SCN) Function
Playing the first 10 seconds of each file on USB and cancelling the function.
Repeat Play Selector (RPT)
Playing selected file repeatedly or all files in a directory.
USB Player Functions (Continued)
Random Play Selector (RDM)
Playing files on USB in random order and cancelling the mode.
Directory Navigation: Down
Navigating to the previous directory while playing MP3.
Directory Navigation: Up
Navigating to the next directory while playing MP3 and handling files without directories.
Bluetooth System Introduction
Bluetooth System Overview
Bluetooth features for wireless connection, hands-free system, and music playback.
Bluetooth Indicator Status
Display of Bluetooth device connection status.
Mobile Phone Battery Indicator
Indication of mobile phone battery condition.
Mobile Phone Signal Indicator
Indication of mobile phone network signal strength.
Bluetooth System Functionality
Bluetooth Pairing Process
Establishing a Bluetooth connection by pairing mobile phone or music player.
Bluetooth Device Pairing Method
Step-by-step pairing process including finding, selecting, and entering PIN code.
Bluetooth System Functionality (Continued)
Disconnecting a Bluetooth Device
Steps to disconnect a paired Bluetooth device.
Selecting a Bluetooth Device for Connection
Selecting a previously paired device for connection from a list.
Bluetooth System Functionality (Continued)
Deleting a Paired Bluetooth Device
Procedure to delete a paired Bluetooth device from the radio's memory.
Basic Telephone Hands-Free Operation
Using Bluetooth for hands-free calls, answering, ending, and making calls.
Bluetooth System Functionality (Continued)
Redialing Last Call Number
Redialing the last dialed number using the SEND button.
Switching to Private Mode During Call
Switching between hands-free and private call modes during a conversation.
Bluetooth Audio Player Functionality
Playing music using Bluetooth audio, including track selection and pausing/resuming.
Simultaneous Connection of Devices
Connecting both a mobile phone and music player simultaneously for calls and music.
Bluetooth System Settings
Automatic Call Answer Feature
Enabling automatic call answer and setting delay time.
Calling Voice Volume Adjustment
Adjusting the volume for incoming calls heard through the radio.
Ring Volume Adjustment
Adjusting the volume for incoming phone ring tones heard through the radio.
7) Hands-Free System (Option) (Continued)
Handsfree Jack Socket Connection
Connecting jack cable for hands-free calls and using special adapters.
Hands-Free Indicator Lamp
Indicator lamp showing when hands-free mode is selected.
Remote Controller Functions (Continued)
Handsfree Microphone Function
Function of handsfree microphone for voice transmission.
Seek Button Functionality
Stopping radio at next frequency or selecting MP3 songs from USB.
Mute Button Functionality
Muting or cancelling mute during broadcasting.
Mode Button Selection
Selecting desired mode (Radio, MP3, AUX).
Remote Controller Functions (Continued)
Radio Calling Mode Button
Activating/deactivating radio handsfree function and LED indicator status.
Talk Button Operation
Connecting calls via talk button (push-to-talk) and listening restrictions.
Handsfree Jack Connection
Connecting jack cable for radio handsfree calls.
Operation Camera Set Functions
Setting Camera Channels
Setting the number of camera channels on screen (1, 2, or 4 CH).
Camera System Settings
Gear Linkage Mode
Automatic switching of camera channels based on gear state (forward/backward).
Brightness Setting Adjustment
Adjusting the display brightness.
Language Setting Selection
Setting the display language from multiple options.
4. Operator Maintenance and Care
1. Daily Safety Inspection
Operator's responsibility for checking truck condition and safety before operation.
Visual Checks of Truck Components
Performing a visual inspection of major components, labels, fluids, and critical parts.
1. Daily Safety Inspection (Continued)
2) Functional Checks Procedure
Checking operation of truck controls, systems, and accessories after visual inspection.
3) Concluding the Inspection
Procedures for concluding inspection, including using "Out of service" tags for unsafe trucks.
2. Suggestions for New Truck Operation
Initial 100 Hours Operation Guidelines
Recommendations for initial 100 hours operation to enhance performance and avoid excessive use.
Initial Hours Replacement Schedule
Schedule for replacing engine oil, filters, and other items after initial operation hours.
5. Starting and Operating Procedures
1. Before Operating the Truck
Importance of reading the manual, being trained, and ensuring safe operation.
2. Check Before Operation
1) OSHA Requirement for Inspection
OSHA requirement for truck users to examine trucks before shifts for safe working order.
2) Thorough Walk-Around Check
Performing a walk-around check before starting the engine for personal safety and truck longevity.
3. Check Before Starting Engine
1) Check for Water or Oil Leakage
Checking for water, oil, or hydraulic leaks and examining cabin, backrest, and forks for damage.
2) Check Tire Air Pressure and Rim
Checking tire air pressure and torque, with warnings about high inflation pressure.
3. Check Before Starting Engine (Continued)
3) Check Coolant Level
Checking coolant level and adding antifreeze mixture, with safety precautions about hot engine.
4) Check Engine Oil Level
Checking engine oil level using dipstick and adding oil if necessary.
3. Check Before Starting Engine (Continued)
5) Check Fan Belt Tension
Methods for checking fan belt tension, inspecting for damage, and checking belt condition.
6) Check Battery Status
Checking, recharging, or replacing the battery, with maintenance and safety service needs.
3. Check Before Starting Engine (Continued)
7) Check Brake Cooling Oil Level
Checking brake cooling oil level and adding oil if insufficient, with warnings about hot oil.
8) Check Hydraulic Oil Level
Checking hydraulic oil level using the level gauge and noting differences based on mast equipment.
9) Check Prefilter
Inspecting and draining the collection bowl of water daily and replacing the element every 500 hours.
4. Seat Adjustment Procedures
1) Seat Adjustment Controls
Adjusting seat for forward/backward, upward/downward, reclining, armrest, and cushion.
2) Seat Belt Buckling Instructions
Importance of buckling seat belt for safety and checking its condition periodically.
5. Starting from a Safe Condition
1) Ensure Safe Starting Condition
Checklist for safe starting: seated, seat belt buckled, parking brake applied, forks lowered.
2) Set Gear Selector to Neutral
Requirement to start the truck only in NEUTRAL position.
7. Starting and Stopping the Engine
1) Check Indicator Lights Before Starting
Checking indicator lights and buzzer upon turning the key to ON position.
2) Starting Engine in Normal Temperature
Procedure for starting the engine in normal temperature conditions, including sounding horn.
4) Inspection After Engine Start
Post-Start Checks
Post-start checks including hydraulic oil level, leakages, warning lamps, engine sound, and exhaust color.
Engine Exhaust Color Check
Criteria for checking engine exhaust gas color (colorless, black, white).
Fuel Tank Level Check
Checking fuel tank level, refueling precautions, and filling procedures.
5) Warning Lamps Check
Check Warning Lamps
Visual guide to various warning lamps and their significance.
Check Steering Wheel Play
Checking steering wheel play and repair if it exceeds specified limits.
Check Lift Chain Tension
Checking lift chain tension and adjusting it, with a warning not to put hands in the mast.
Check Steering Wheel Operation
Checking steering wheel for wobble, sudden pull, or abnormal heaviness.
Check Rear View Mirror
Adjusting rearview mirror for best rearward visibility.
9. Levers and Pedals
1) Positioning Forks and Mast
Positioning forks and mast correctly for travel, preventing obstructions and reducing wear.
Lever and Pedal Operations
2) Selecting Direction of Travel
Operation of the gear selector lever for forward, neutral, and reverse.
3) Using the Accelerator Pedal
Using the accelerator pedal to move the truck at the desired speed.
4) Braking Pedal Operation
Using the brake pedal to stop the truck smoothly and safely.
5) Inching Pedal Usage
Using inching and accelerator pedals together for precise travel speed control.
10. Traveling of the Truck
1) Basic Traveling Operation
Traveling posture and operation steps after warm-up, including releasing brake and using accelerator.
Traveling Operation Steps
Step-by-step procedure for moving the truck after engine warm-up.
Changing Direction and Speed
Operation of gear selector lever for direction and speeds, and neutral lock function.
10. Traveling of the Truck (Continued)
Precautions During Travel
Precautions when traveling, including avoiding abrupt deceleration, checking direction before changing, and avoiding high-speed turns.
Truck Turning Procedure
How to turn the truck using the steering wheel and measuring turning range.
Driving Precautions
Actions when warning lamps light up, handling load changes, driving on uneven ground, and avoiding prolonged idling.
Stopping the Truck Safely
6) Stopping the Truck Procedure
Steps for stopping the truck: applying brake, neutral gear, parking brake, and lowering forks.
Stopping the Engine Safely
7) Stopping Engine Safely
Safe engine shutdown procedures, especially when overheated, and post-stop checks.
2) Traveling on a Slope Safely
Safety rules for traveling on slopes, including fork position, turning, parking, and warming up.
11. Operating Safely Guidelines
1) Watch Where You Are Going
Importance of checking path for obstructions and pedestrians, and looking where you drive.
2) Protect Yourself and Others
Operating from designated position, keeping body parts inside, and avoiding mast/lift mechanism contact.
3) No Riders Policy Reminder
Rule against carrying passengers and ensuring only operator is on the truck.
4) Maintain Full Control of Lift Truck
Maintaining full control, avoiding wet/greasy hands, choosing smooth routes, and avoiding sudden movements.
11. Operating Safely Guidelines (Continued)
6) Travel with Fork Carriage Tilted Back
Traveling with carriage tilted back and not elevating load except during stacking.
7) Grades, Ramps, and Inclines Safety
Special care on inclines, traveling straight, not turning on slopes, and applying engine brake.
6) Practice Safe Operation Always
Responsibility for safe driving, familiarity with manual, observing rules, and checking gauges.
12. Load Handling Procedures
1) General Load Handling Guidelines
Handling loads within rated capacity, stable loads, keeping load back, and lifting/lowering with vertical mast.
7) Stacking Loads
(1) To Put a Load on a Stack
Steps for stacking a load, including approaching, raising, aligning, and lowering the load.
7) Stacking Loads (Continued)
(2) To Move a Load from a Stack
Procedure for moving a load from a stack, including alignment, fork adjustment, and travel path check.
13. Shut Down Procedures
1) Safety Rules When Leaving Truck
Safety rules for parking, including safe area, no grades, and no blocking routes.
2) Steps Before Leaving Operator Position
Steps before leaving operator's position: stopping truck, neutral gear, parking brake, lowering forks.
3) Additional Steps for Unattended Truck
Additional steps for unattended trucks: tilting mast, turning off switch, blocking wheels, and engine idling for protection.
14. Storage Procedures
1) Before Storing the Truck
Instructions for preparing the truck for storage, including cleaning, covering, and adding antifreeze.
2) During Storage Operations
Operating the engine periodically to maintain oil film and improve ventilation.
3) After Storage Procedures
Procedures for bringing the truck back into service after storage, including draining water and lubricating.
15. Transport Precautions
1) Loading and Unloading Precautions
Precautions for transport, including checking clearance, removing slippery material, and securing ramps.
6. Emergency Starting and Towing
1. How to Tow a Disabled Truck
Procedures for safely towing a disabled lift truck, including equipment and precautions.
7. Planned Maintenance and Lubrication
1. Introduction to Planned Maintenance
Importance of planned maintenance performed by trained personnel for safety and performance.
3. Instructions Before Maintenance
1) Maintenance Interval Guidelines
Inspecting and servicing the truck based on LCD service meter, with adjusted intervals for operating conditions.
2. Maintenance Precautions
General Precautions Before Maintenance
Precautions before starting maintenance, including knowledge of truck, monitor function, and consulting dealer.
Proper Maintenance Guidelines
Guidelines for replacing parts, using genuine parts, recommended oil, and cleaning.
Hydraulic Hose/Pipe Installation Precautions
Precautions for installing hydraulic hoses, ensuring no damage, avoiding contamination, and using genuine parts.
5. Periodical Replacement of Safety Parts
Schedule for Periodic Safety Part Replacement
Schedule for periodic replacement of safety parts based on visual inspection and recommended intervals.
Emission-Related Components Warranty
Hyundai's warranty obligation for emission-related components under EPA regulations.
4. Planned Maintenance Intervals
1) Major Components Location
Diagram showing the location of major components for planned maintenance.
2) Maintenance Check List: Intervals
Every 10 Hours Service Checks
Detailed list of check items and services for every 10 hours, including visual inspection, function tests, and fluid levels.
Every 50 Hours Service Checks
Detailed list of check items and services for every 50 hours, including transmission oil, lubrication, and tightening torques.
Maintenance Check List: Intervals (Continued)
Initial 50 Hours Service Items
Maintenance items for the initial 50 hours of service, like engine oil and pilot line filter.
Initial 100 Hours Service Items
Maintenance items for the initial 100 hours of service, like axle gear oil and transmission oil.
Every 250 Hours Service Items
Maintenance items for every 250 hours, including lubrication of various components.
Every 500 Hours Service Items
Maintenance items for every 500 hours, including checking and tightening bolts, battery, and filters.
Maintenance Check List: Intervals (Continued)
Every 1000 Hours Service Items
Maintenance items for every 1000 hours, including air cleaner element, hydraulic oil return filter, and transmission oil.
Every 2000 Hours Service Items
Maintenance items for every 2000 hours, including hydraulic tank suction strainer and radiator coolant.
Every 4000 Hours Service Items
Maintenance items for every 4000 hours, including aftertreatment DEF dosing unit filter.
Every 5000 Hours Service Items
Maintenance item for every 5000 hours, including hydraulic oil.
Maintenance Check List: When Required
Items Checked When Required
Maintenance items to be checked when required, such as fuel system, DEF level, and tire air pressure.
5. Maintenance Chart
1) Maintenance Locations Diagram
Diagram showing locations for maintenance checks and points.
2) Maintenance Check List (Intervals)
Every 10 Hours Service Details
Detailed list of check items and services for every 10 hours, including visual inspection, function tests, and fluid levels.
Every 50 Hours Service Details
Detailed list of check items and services for every 50 hours, including transmission oil, lubrication, and tightening torques.
6. How to Perform Planned Maintenance
1) Visual Inspection of Truck
Performing visual inspection of truck, components, and nameplates/decals.
2) Cabin Inspection
Checking cabin and safety devices for proper placement, damage, and secure attachment.
3) Load Handling Components Inspection
Inspecting mast assembly, rollers, chains, cylinders, and connections for wear and leaks.
7. Service Instructions
1) Check Engine Oil Level
Checking engine oil level using dipstick, adding oil if low, and replacing if contaminated.
2) Engine Oil and Filter Replacement
Procedure for replacing engine oil and filter, including warming engine and draining oil.
13) Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter
(1) Remove Filter Components
Procedure for removing the DEF filter cap, equalizing element, and dosing unit filter element.
(2) Clean and Inspect Filter Cap
Inspecting DEF dosing unit filter cap and threads for cracks or damage.
13) Aftertreatment Diesel Exhaust Fluid Dosing Unit Filter (Continued)
(3) Install Filter Components
Installing DEF filter components, cap, and tightening torque, with system priming information.
14) DEF/AdBlue® Tank Level Check
Checking DEF/AdBlue® tank level and warnings against tampering with the aftertreatment system.
26) Tire Replacement Procedures
1) Tires Requiring Replacement
Identification of tires needing replacement due to damage or wear.
2) Tire Separation Procedure
Steps for separating tires, including lowering bucket and applying parking brake.
26) Tire Replacement Procedures (Continued)
3) Tire Installation Direction
Ensuring correct valve orientation during tire installation.
4) Mounting Tire Correctly
Steps for lightly tightening nuts, lowering jack, and tightening to specified torque.
8. Electrical System Checks
1) Wiring and Gauges Check
Checking regularly and repairing loose or malfunctioning gauges.
2) Welding Repair Precautions
Following procedures before welding, including shutting off engine and disconnecting battery.
9. Air Conditioner and Heater
1) Cleaning and Replacing Filter
Opening door, loosening bolt, and removing recirculation plenum assembly for filter service.
2) Precautions for Air Conditioner Use
Tips for using AC: opening window, avoiding overcooling, and changing air.
3) Check During Season
Refrigerant replenishment and maintenance service for cooling performance.
4) Check During Off-Season
Operating AC periodically to prevent oil film loss in compressor.
5) Refrigerant Information
Equipment Refrigerant Details
Information on refrigerant type, quantity, and Global Warming Potential (GWP).
Environmental and Safety Precautions
Environmental impact of HFC-134a and safety measures for handling refrigerant.
Safety Precautions for Technicians
Work on AC system by qualified technicians only, wearing protective gear.
Action in Case of Exposure
First aid measures for eye contact, skin contact, and inhalation of refrigerant.
10. Replacement and Check Procedures
1) Wiring and Gauges Check
Checking regularly and repairing loose or malfunctioning gauges.
2) Battery Maintenance
Cleaning terminals, recycling batteries, and safe removal/installation procedures.
3) Tire Replacement Procedures
1) Tires Requiring Replacement
Identification of tires needing replacement due to damage or wear.
2) Tire Separation Procedure
Steps for separating tires, including lowering bucket and applying parking brake.
3) Tire Installation Direction
Ensuring correct valve orientation during tire installation.
4) Mounting Tire Correctly
Steps for lightly tightening nuts, lowering jack, and tightening to specified torque.
5) Precautions for Tire Inflation
Warnings about high tire pressure and careful inflation adjustments.
6) Functional Tests
(1) Horn Test
Pressing horn button to check function and reporting failures.
(2) Hour Meter Check
Checking hour meter operation while engine runs and recording reading.
(3) Indicator Lights Check
Checking all lights for functioning and indicating normal truck operation.
(4) Service Brakes and Inching Pedal Test
Testing service brake pedal application and inching pedal interconnectivity.
6) Functional Tests (Continued)
(5) Parking Brake Test
Checking parking brake function and holding capability on a grade.
(6) Lift Mechanisms and Controls Check
Testing mast tilt and lift movements for smoothness and checking chain tension.
(7) Auxiliary Controls Test (Option)
Testing control levers for correct function of any attached equipment.
6) Functional Tests (Continued)
(8) Steering System Inspection
Inspecting steering system for looseness, damage, leaks, and checking handwheel movement.
(9) Direction Control, Braking and Inching Tests
Testing direction control, braking, and inching pedal operations for smooth and equal response.
7) Lubrication Procedures
(1) Truck Chassis Inspection and Lubrication
Inspecting and lubricating chassis components, steering system, and linkage points.
(2) Mast and Tilt Cylinder Lubrication
Cleaning and lubricating tilt cylinder rod end bushings and mast mounting pin.
(3) Lift Chains Lubrication
Lubricating mast rail lift and carriage chains with HYUNDAI chain lube.
10) Lift Chain Maintenance
(1) Lift Chain Inspection and Measurement
Inspecting lift chains for wear, rust, corrosion, and checking tension.
(2) Lift Chain Lubrication
Lubricating lift chains regularly for safe operation and longer life using HYUNDAI lube.
12. Cold Weather Operation
1) Preparation for Low Temperature
Replacing lubrication oil, using low pour point fuel, and filling cooling system with antifreeze.
2) Battery Care in Cold Weather
Maintaining battery charge and insulating against cold to ensure easy starting.
3) Care After Daily Operation
Draining water from fuel system and filling fuel tank to prevent condensation.
13. Recommendation Table for Lubricants
1) New Truck Lubricant Specifications
Table of recommended fuels, coolants, and lubricants for new trucks.
8. SPECIFICATIONS
1. Specification Table
Table detailing key specifications of the lift truck models.
2. Specification for Major Components
(1) Engine Specifications
Detailed specifications for the Cummins QSB6.7 engine.
(2) Main Pump Specifications
Specifications for the variable displacement axial piston pump.
(3) Main Control Valve Specifications
Specifications for the sectional main control valve.
2. Specification for Major Components (Continued)
(4) Steering Unit Specifications
Specifications for the load sensing steering unit.
(5) Power Train Devices
Specifications for torque converter, transmission, axle, wheels, brakes, and steering.
2. Specification for Major Components (Continued)
(1) Engine Specifications (160D-9)
Detailed specifications for the Cummins QSB6.7 engine model 160D-9.
(2) Main Pump Specifications
Specifications for the variable displacement axial piston pump.
(3) Main Control Valve Specifications
Specifications for the sectional main control valve.
2. Specification for Major Components (Continued)
(4) Steering Unit Specifications
Specifications for the load sensing steering unit.
(5) Power Train Devices
Specifications for torque converter, transmission, axle, wheels, brakes, and steering.
7. Mast and Fork Problems
Mast Problems and Solutions
Troubleshooting for fork lowering/elevation issues, mast lifting smoothness, and abnormal noises.
7. Mast and Fork Problems (Continued)
Fork Problems and Solutions
Troubleshooting for fork abrasion, distortion, and fatigue failure.
10. Testing and Adjusting: Engine System
1) Ease of Starting and Noise Check
Checking ease of starting, smooth rotation, and absence of abnormal noise.
2) Idling Performance Check
Checking steady engine rotation, smooth acceleration, and idling speed range.
3) Accelerator Pedal Operation Check
Checking accelerator pedal for smooth operation, engine speed changes, and exhaust gas color.
2. Drive System Checks
1) Gear Selector Lever Operation
Neutral starting and shifting between forward/reverse.
2) Oil Leakage Check
Checking for oil leaks from torque converter, transmission, or control valve.
3) Pedal Adjustment
Adjusting accelerator and brake pedal angles for proper operation.
3) Pedal Adjustment (Continued)
(3) Inching Pedal Adjustment
Adjusting inching pedal angle and interconnectivity with brake pedal.
3. Travel System Checks
(1) Tires Inspection
Checking tire pressure, visually for cracks/damage, and tread wear.
(2) Hub Nuts Check
Checking for loose hub nuts and tightening to specified torque.
(3) Rim Side Ring Inspection
Checking rim side ring for deformation or cracks.
(4) Steering Axle Clearance Check
Checking steering axle clearance and measuring between center pin and bushing.
(5) Drive Axle Inspection
Checking drive axle mounting bolts and welds for deformation or cracks.
4. Steering System Checks
1) Steering Wheel Play Check
Measuring steering wheel movement range and checking play.
2) Knuckle Inspection
Checking knuckle visually or using crack detection method for bends.
3) Steering Axle Camber Check
Measuring camber and turning radius, adjusting stopper bolt if needed.
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