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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
Related Manuals for Hyundai 180D-9B
Summarization of Contents
Foreword
A Message to Hyundai Lift Truck Operators
Introduction for lift truck operators, emphasizing safety and proper use.
Introduction
Welcome to HYUNDAI lift trucks and overview of the manual's content.
How to Use This Manual
Guide on how to navigate and understand the manual's structure and content.
EC Regulation Approved
Information on EC regulations related to noise levels for approved models.
Safety Labels
Location of Safety Labels
Diagrams showing the placement of various safety labels on the truck.
Description of Safety Labels
Detailed explanations and warnings associated with specific safety labels.
Guide
Direction
Defines truck directions (front, rear, left, right) for travel.
Serial Number
Information on locating truck and engine serial numbers for identification.
Symbols
Explanation of symbols used in the manual for safety and information.
1. Safety Hints
Daily Inspection
Procedure for inspecting the truck at the beginning of each shift.
Do's and Don'ts
Key safety practices and behaviors to follow and avoid during operation.
Seat Belts
Importance of wearing seat belts and their function in reducing injuries.
No Riders
Rules prohibiting unauthorized passengers on the lift truck.
Pedestrians
Safety advice for interacting with pedestrians in the work area.
Operator Protection
Guidelines for operator safety within the cabin and overhead guard.
Fork Safety
Precautions for safe use of forks, including load handling and personnel safety.
Pinch Points
Warnings about hazardous pinch points in the mast and related mechanisms.
Travel
Safe travel practices with loads, including visibility and load stability.
Grades, Ramps, Slopes and Inclines
Safe operation procedures when navigating inclines and ramps.
Tip Over
Information on causes of tip-overs and actions to take in case of a tip-over.
Surface and Capacity
Considerations for different surfaces and load capacity for safe operation.
Parking
Correct procedures for safely parking the lift truck.
Refueling
Safety precautions to follow during the refueling process.
Step
Safe practices for getting on and off the truck.
Operator's Safety Rules
Essential safety rules for lift truck operators, including OPSS.
Side Shift
Safe operation guidelines for using the side shift function.
2. Operating Hazards
Loose Loads
Hazards associated with carrying loose or unbalanced loads.
Long and Wide Loads
Safety considerations when handling long or wide materials.
Rear Swing
Warning about the rear swing of the truck during turns.
Low Overhead Clearance
Hazards related to low overhead structures and clearance.
Fast Turns and High Loads
Risks associated with making fast turns or handling high loads.
Right Angle Stacking
Safe practices for stacking loads at right angles.
Chain Slack
Hazards related to slack lift chains and how to prevent them.
Pallets and Skids
Safety precautions when using pallets and skids.
Caution for Electrical Lines
Safety warnings and minimum safe separation distances for electrical lines.
Lifting Loads
Safety rules for lifting loads, including personnel and equipment safety.
Side Shift
Hazards and safe operation of the side shift function with loads.
Fork Positioner
Safe operation of the fork positioner to avoid dropping loads.
3. Know Your Truck
General Locations
Diagram identifying major components of the lift truck.
Name Plate and Safety Warning Decal
Information on nameplates and operator safety warning decals.
Cab Devices
Overview of devices and systems located within the operator's cab.
Cluster
Description of the instrument cluster, gauges, lamps, and buttons.
Transmission Message Display
Explanation of transmission messages and AEB-mode displays.
Switches
Identification and function of various switches in the operator's cab.
Control Device
Description of levers and pedals for controlling truck functions.
Air Conditioner and Heater
Operation and maintenance of the cab's air conditioning and heating system.
Others
Identification of other components like ECM, TCU, MCU, and connectors.
4. Operator Maintenance and Care
Daily Safety Inspection
Detailed visual and functional checks required for daily operation.
Suggestion for New Truck
Recommendations for operating a new truck during the initial 100 hours.
Fuel Safety Practices
Essential safety guidelines for refueling diesel trucks.
5. Starting and Operating Procedures
Before Operating the Truck
Prerequisites and safety checks before operating the lift truck.
Check Before Operation
Walk-around checks and inspection chart before starting the engine.
Check Before Starting Engine
Detailed checks for leaks, tire pressure, and fluid levels before engine start.
Seat Adjustment
Instructions for adjusting the operator's seat for comfort and safety.
Starting from a Safe Condition
Ensuring a safe condition before starting the truck.
General Starting and Operating Tips
Important tips for starting the engine and general safe operation.
Starting and Stopping the Engine
Procedures for starting and stopping the engine, including cold weather.
Warming-up Operation
Proper procedures for warming up the engine and hydraulic system.
Levers and Pedals
Operation of various levers and pedals for truck control.
Traveling of the Truck
Guidelines for safe truck traveling, including posture, direction, and speed.
Operating Safely
General safety rules for operating the lift truck in various conditions.
Grades, Ramps, and Inclines
Specific safety procedures for operating on slopes and inclines.
Load Handling
Safe practices for handling, picking up, moving, and stacking loads.
Shut Down Procedure
Correct steps for shutting down and parking the lift truck safely.
Storage
Instructions for safely storing the lift truck for extended periods.
Transport
Precautions for loading and unloading the truck for transportation.
Loading and Unloading by Crane
Safe procedures for hoisting the truck using a crane.
6. Emergency Starting and Towing
How to Tow a Disabled Truck
Step-by-step instructions for safely towing a disabled lift truck.
Parking Brake Release
Procedure for releasing the parking brake in emergency situations.
How to Use Battery Jumper Cables
Safe procedures for jump-starting a lift truck using jumper cables.
7. Planned Maintenance and Lubrication
Introduction
Overview of planned maintenance importance and benefits.
Safe Maintenance Practices
General safety guidelines for performing maintenance on industrial trucks.
Instructions Before Maintenance
Prerequisites and precautions to take before starting maintenance.
How to Perform Planned Maintenance
Detailed procedures for performing visual inspections of key components.
Lubrication
Lubrication points and intervals for various truck components.
Service Instruction
Detailed instructions for servicing engine oil, filters, and cooling system.
Handling Truck in Extremely Hot Places
Specific precautions for operating the truck in very hot environments.
Cold Weather Operation
Guidelines for operating the truck in cold weather conditions.
Recommendation Table for Lubricants
Table of recommended fuels, coolants, and lubricants for the truck.
Fuel and Lubricants
Chart detailing fluid types, capacities, and ambient temperature recommendations.
8. Specifications
Specification Table
Technical specifications and dimensions of the lift truck models.
Specification for Major Components
Detailed specifications for key components like engine and pumps.
Tightening Torque
Table of specified tightening torques for various bolts and nuts.
9. Troubleshooting
Engine System
Troubleshooting guide for common engine system problems and remedies.
Electrical System
Troubleshooting guide for common electrical system issues.
Torque Flow System
Troubleshooting guide for torque flow system issues.
Steering System
Troubleshooting guide for common steering system problems.
Brake System
Troubleshooting guide for common brake system issues.
Hydraulic System
Troubleshooting guide for common hydraulic system problems.
Mast and Fork
Troubleshooting guide for mast and fork related problems.
Forks
Troubleshooting guide for fork wear, distortion, and fatigue issues.
10. Testing and Adjusting
Engine System
Tests for engine starting, noise, idling, and accelerator pedal operation.
Drive System
Tests and adjustments for the gear selector lever, oil leakage, and pedals.
Travel System
Tests and checks for tires, hub nuts, rim side ring, steering axle, and drive axle.
Steering System
Tests and checks for steering wheel, knuckle, and steering axle.
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