Hyundai 250D-9, Manual

Page 1: ...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...

Page 2: ...ction 4 1 2 Suggestion for new truck 4 3 3 Fuel safety practices 4 4 5 STARTING AND OPERATING PROCEDURES 5 STARTING AND OPERATING PROCEDURES 1 Before operating the truck 5 1 2 Check before operation 5...

Page 3: ...ir conditioner and heater 7 48 10 Replacement and check 7 49 11 Handling truck in extremely hot places 7 62 12 Cold weather operation 7 63 13 Recommendation table for lubricants 7 64 14 Fuel and lubri...

Page 4: ...ur work areas and avoid or correct them It is important that you know and understand the information in this manual and that you know and follow your company safety rules Be sure that your equipment i...

Page 5: ...potential source of danger to the operator and to other personnel working near it As with all quality equipment keep your lift truck in good operating condition by following the recommended schedule...

Page 6: ...ng and adjusting The descriptions and specifications included in this manual were in effect at the time of printing The descriptions and specifications included in this manual were in effect at the ti...

Page 7: ...es and limitations Follow all instructions in this manual including all symbols and messages to avoid damage to your lift truck or the possibility of any harm to yourself or others This manual is inte...

Page 8: ...EC and EN 12053 are as followings The value of vibrations transmitted by the operator s seat are lower than standard value of 2005 88 EC EC REGULATION APPROVED EC REGULATION APPROVED Model LWA EU only...

Page 9: ...ine wash 13 Start warning 16 Fork positioner LH 17 Fork positioner RH 18 Tire air pressure 19 Noise 20 Model name 21 Tilt cabin warning Up Down 23 Tilt cabin warning 24 Brake cooling oil 25 TCU connec...

Page 10: ...over the radiator Coolant must be checked as specified in Coolant must be checked as specified in the maintenance chart the maintenance chart 2 2 25L7A0OM10 RADIATOR CAP RADIATOR CAP ltem 6 This warni...

Page 11: ...or the regulated tire Refer to page 5 3 for the regulated tire air pressure A and B air pressure A and B 92AT 00830 kgf cm A PSI B 5 25L7A0OM08 HOOK HOOK Item 4 This warning label is positioned on the...

Page 12: ...ement of the truck shall be possible only if the operator is in the normal operating position Transmission will automatically shift to neutral upon the exiting of the operator The Forward Reverse leve...

Page 13: ...of the fuel system from the air bleed fitting to fuel return line This feature can be used to check the operation of lift pump and to fill the low pressure side fuel system after the services Start Pr...

Page 14: ...ing unexpectedly unexpectedly do not change the hand do not change the hand pump lever manually when opening pump lever manually when opening cab cab Refer to page 3 32 for tilt switch Refer to page 3...

Page 15: ...rness Do not touch the cabin tilting cylinder head during the operation 91FT 13320 2 Be sure the engine working during the use of air compressor 1 Park on a flat place to use the air compressor 3 Duri...

Page 16: ...if it is handled in extremely dangerous if it is handled in the wrong way Always observe the the wrong way Always observe the following precautions following precautions Never make any hole in the acc...

Page 17: ...ioned on the top side of the air tank Do not touch the cylinder head during the Do not touch the cylinder head during the operation or it may cause severe burn operation or it may cause severe burn 23...

Page 18: ...tertreatment device or Do not touch the aftertreatment device or it may cause severe burn When the it may cause severe burn When the engine is running or immediately after engine is running or immedia...

Page 19: ...02 ENGINE SERIAL NUMBER The numbers are located on the engine name plate 2 250D9FW03 GUIDE GUIDE 1 DIRECTION 1 DIRECTION 2 SERIAL NUMBER 2 SERIAL NUMBER Important safety hint Important safety hint It...

Page 20: ...n 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 They know how to make repai...

Page 21: ...DON TS 2 DO S AND DON TS D35AOM03 Do wear safety equipment when required D35AOM05 Don t mix drugs or alcohol with your job Don t block safety or emergency equipment 40B9OM04 D35AOM02 Don t smoke in NO...

Page 22: ...in rainy day Exclude the truck equipped cabin Exclude the truck equipped cabin 250D9OM07 Exhaust gas is dangerous Do not operate the truck at the inhouse if possible Provide adequate ventilation when...

Page 23: ...s can reduce injuries Seat belts can reduce injuries 160D7OM11 Always buckle up for the truck equipped Always buckle up for the truck equipped with safety belt with safety belt 160D7OM09 3 SEAT BELTS...

Page 24: ...1 5 250D9OM12 250D9OM14 The operator is the only one who should be on a truck Never transport personnel on the forks of a lift truck 1 2 4 NO RIDERS 4 NO RIDERS...

Page 25: ...dway you do Sound your horn at all intersections or blind spots 250D9OM05 Watch for people in your work area even if your truck has warning lights or alarms People may not watch for you Watch for peop...

Page 26: ...within the confines of the truck Do not operate truck without cabin or Do not operate truck without cabin or overhead guard unless condition prevent overhead guard unless condition prevent use of it...

Page 27: ...ks D255OM17A There is special equipment to raise people for overhead work DO NOT USE LIFT TRUCKS 250D9OM14 Always lower the load slowly Raise and lower with mast vertical or tilted slightly back Never...

Page 28: ...e the mast as a ladder Don t use the mast as a ladder 250D9OM62 Never try to repair the mast carriage Never try to repair the mast carriage chain or attachment by yourself Always chain or attachment b...

Page 29: ...250D9OM18 When handling bulky loads that restrict your vision operate your truck in reverse to improve visibility Be sure to pivot in the seat to give maximum visibility 250D9OM25 Unstable loads are...

Page 30: ...M33 Unloaded Forks downgrade Loaded Forks upgrade 1 2 Never turn on a grade either loaded or unloaded Never turn on a grade either loaded or unloaded 10 GRADES RAMPS SLOPES AND INCLINES 10 GRADES RAMP...

Page 31: ...ngitudinal tip over can occur by driving with the load down slope on a steep grade Lateral and longitudinal tip over can occur if the truck is driven over objects on the floor or ground off the edge o...

Page 32: ...as illustrated right Brace yourself as illustrated right 1 Make sure your seat belt is fastened securely if the truck is equipped with seat belt 2 Stay in your seat 3 Grip the wheel 4 Brace your feet...

Page 33: ...truck to tip over or lose traction for braking or driving Know the weight of your truck and load Know the weight of your truck and load Especially when using elevators Know Especially when using eleva...

Page 34: ...p before leaving truck Be sure travel control is in NEUTRAL 250D9OM42 Lower forks fully to floor and tilt forward ON OFF START 1 2 250D9OM44 Set parking brake Position 1 OFF Release Position 2 ON Lock...

Page 35: ...g oil check around truck for oil leakage 250D9OM47 Keep away from fire when adding oil or during operation DIESEL 250D9OM48 After adding oil wipe off any oil spilled on truck 250D9OM49 1 2 3 14 REFUEL...

Page 36: ...1 17 When getting on or off the truck use the step provided 250D9OM50 Do not jump up or down from the truck 250D9OM52 1 2 15 STEP 15 STEP...

Page 37: ...warning This function works when the key switch is not only ON or START position but also OFF position Alarm sounds in 2 seconds from the driver s off the seat with the parking brake released To rele...

Page 38: ...Never carry loose or uneven material 250D9OM53 Center wide loads 250D9OM55 Stack and band loose material D35AOM41 Avoid sudden braking or starting When the truck is loaded do not drive at When the tr...

Page 39: ...A long load reduces the capacity of the A long load reduces the capacity of the truck Know and understand your truck truck Know and understand your truck load rating load rating 2 LONG AND WIDE LOADS...

Page 40: ...uck over or spill a load truck over or spill a load 250D9OM74 Slow down before turning Slow down before turning The truck can tip over The truck can tip over 250D9OM46 Turn too sharp with a raised loa...

Page 41: ...hains mean rail or carriage hang up up Raise the forks before you move or Raise the forks before you move or broken chains can result broken chains can result In case forks with loads are stuck while...

Page 42: ...g off the electric current off the electric current Jump off the truck without contacting the Jump off the truck without contacting the truck when you need to get off truck when you need to get off Do...

Page 43: ...sons to stand or Never permit any persons to stand or pass under lifted load pass under lifted load 250D9OM58 250D9OM60 Never use wire rope to lift a load Never use wire rope to lift a load 10 LIFTING...

Page 44: ...r 8 Cabin 9 Head light fender 10 Work lamp mast 11 Work lamp cabin rear 12 Operator s seat 13 Bonnet 14 Counterweight 15 Rear wheel 16 Front wheel 17 Rear combination lamp 16 9 7 10 15 12 13 17 14 11...

Page 45: ...marked to identify the attachment s including the weight of the truck attachment combination and truck capacity with the attachment Capacity rating load center and lifting height data Shows the maximu...

Page 46: ...decals Operator Tip over warning decal This decal is located on cabin s upper left side frame Its purpose is to remind the operator that staying in the seat provides the best chance of avoiding injur...

Page 47: ...witch Accelerator pedal Operator seat Brake pedal Handsfree Remote controller The ergonomically designed console box and suspension type seat provide the operator with comfort ELECTRONIC MONITOR SYSTE...

Page 48: ...s of the truck Warning lamps Indicate abnormality of the truck Pilot lamps Indicate operating status of the truck LCD Display the truck model error code and engine speed etc Buttons Select the truck m...

Page 49: ...eed until the indicator is in the operating range If the indicator is in the red range turn OFF the engine and check the radiator and engine If the gauge indicates red range even though the truck is o...

Page 50: ...SCR cleaning warning lamp Engine stop warning lamp Engine oil pressure warning lamp Water in fuel warning lamp Brake system pressure warning lamp Brake system temp warning lamp Transmission error warn...

Page 51: ...omes ON during engine operation Fill the fuel immediately when the lamp is turned ON This lamp operates by the vacuum caused inside when the filter of air cleaner is clogged Check the filter and clean...

Page 52: ...ing operation stop the engine and check the truck This lamp lights ON and the information window of the LCD shows the error code when an error occur in the transmission Immediately pull the truck to a...

Page 53: ...arning Flash On DEF level 0 Engine error code 3547 3714 50 derate 30 min DEF level final derate warning Flash On On Engine error code 3712 Contact Hyundai service center or dealer Manual SCR cleaning...

Page 54: ...r detail DEF Diesel Exhaust Fluid low warning lamp 14 When this warning lamp lights ON stop the engine immediately and and check the DEF level and related parts of the engine Please contact your Hyund...

Page 55: ...cleaning inhibit pilot lamp HEST pilot lamp Preheater pilot lamp Fuel warmer pilot lamp Inching pilot lamp Expendables replacement indicator lamp Right turning pilot lamp Parking brake pilot lamp Head...

Page 56: ...warmer pilot lamp 6 50D9CD14 OPSS pilot lamp 7 This signal lamp lights ON when the operator leaves the seat Powered travel movement of the truck shall be possible only if the operator is in the normal...

Page 57: ...ill be common for the lamp to illuminate on and off during normal equipment operation as the engine completes the SCR cleaning HEST High exhaust system temperature pilot lamp 9 50D9CL003 This pilot la...

Page 58: ...Move in menu left up right down Decrease Increase input value When the warning and pilot lamps occur over six you can display next lamps by push the button Buzzer stop ESC button 1 Menu button Move bu...

Page 59: ...you press right button in the cluster button for about 4 seconds it directly connected to the current failure screen Warning lamp Engine Transmission and Air conditioner 1 2 LCD 5 180D9CD10 180D9CD13...

Page 60: ...istory Maintenance management Signal statue User password change Alternate torque Opening of communication Current history logged history and delete logged fault Replacement Change interval oils and f...

Page 61: ...e a condition Right set rear wheel calibration Center set rear wheel calibration Left set rear wheel calibration Select the Model The initial model is selected at the factory so don t change the diffe...

Page 62: ...tare ON Loaded enter the weight In the loaded from the ground waiting 5 seconds after lift 30 cm Weight correction ON Weight sensor setting Cross section Load weight adjust a b 180D9CD35 1 180D9CD36 1...

Page 63: ...us 50D9CD39 1 50D9CD49 50D9CD50 1 50D9CD51 1 180D9CD35 1 Select the number of points of weight value display Choose using buzzer when over weight Weight display setting Overload warning buzzer c d 180...

Page 64: ...starting Set time 5 minutes for starting In 5 minutes you can restart without password but after 5 minutes you should input password for starting ESL setting 180D9CD59 50D9CD60 180D9CD61K 50D9CD63 50...

Page 65: ...When it is finished OK sign at gear box Press Menu ECS Enter button Start the engine AEB start KEY ON Brake pedal sensor calibration Software version check for MCU Cluster RMCU Vehicle max speed limi...

Page 66: ...you hold down the manual button Automatic The fan rotate in reverse direction at pre set interval Interval 30 minutes 5 hours Time 30 seconds 5 minutes Refer to the page 3 35 for the cooling fan contr...

Page 67: ...50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 Ability to set up the maximum Pull Push Min Max value and neutral value Mid of lever Finger Tip lever set up about 0 5V 2 5V 4...

Page 68: ...e neutral Lever state 2 5V ex If you set up the Upper 0 26 Lower 0 24 Lever operating range will be Upper zone 2 76V 2 5 0 26 4 5V Lever Max value Lower zone 2 26V 2 5 0 24 0 5V Lever Min value 50D9CD...

Page 69: ...of movements according ot the current value Unit Over 110D 9 only mA Under 80D 9 Only ex If the Max value increase the maximum speed will also increase If the Min value increase the minimum speed wil...

Page 70: ...D75 1 180D9CD76 Show the failure status of the current engine transmission and or air conditioner Show the logged fault status from the past of the engine transmission and or air conditioner 180D9CD77...

Page 71: ...ormation below 10 Delete the old item when Information have more than 10 Maintenance management 180D9CD81 180D9CD84 180D9CD82 180D9CD85 180D9CD88 1 180D9CD83 180D9CD87 180D9CD86 Initialize of the past...

Page 72: ...180D9CD89 1 50D9CD90 50D9CD92 180D9CD97 50D9CD1000 180D9CD91 180D9CD93 You should set password by five to ten digit User password change 180D9CD94 1 50D9CD95 1 50D9CD96 1 50D9CD97 1 50D9CD1002 Alterna...

Page 73: ...hen successfully opened RMCU communication except for the RMCU comm Opening of communication 180D9CD98 1 180D9CD102 1 180D9CD102 180D9CD107 180D9CD99 180D9CD104 1 180D9CD101 180D9CD106 180D9CD100 180D...

Page 74: ...D9CD110 180D9CD117 180D9CD111 180D9CD113 50D9CD112 180D9CD114 180D9CD115 Manual Manual setting for LCD brightness Automatic Automatic control of LCD brightness as set level of Day Night Setting day ti...

Page 75: ...ce 13 Multiple language You should set password by five to ten digit Check and change of contact information for customer service Language setting ESL password change A S phone number 180D9CD120 50D9C...

Page 76: ...3 26 Show the maintenance information replacement cycle elapsed time change count alarm information Maintenance management 50D9CD131 50D9CD132 1 50D9CD133 1...

Page 77: ...formation about the selected driving range The automatic range is symbolized by arrows above and below the bar indicator In case of possible errors in the system a wrench appears on the display combin...

Page 78: ...ow raise enging speed E Engine speed too high lower enging speed T Transmission oil temperature too low heat up transmission T Transmission oil temperature too high cool down transmission FT Transmiss...

Page 79: ...eached and hold this position IP Release the pedal slowly until endposition is reached IP blinkt A problem occurred release the pedal slowly until endposition is reached If the expected endposition co...

Page 80: ...t switch Cooling fan control switch opt In decrement switch SCR cleaning switch Seat heater switch opt Hazard switch opt Parking brake switch Auto manual changeover switch Power standard switch Rear w...

Page 81: ...l comes ON When operating the gear selector lever be sure to release the parking brake If the truck is operated with the parking brake engaged the brake will overheat and may cause the brake system to...

Page 82: ...he bottom of the switch fully for the autoshift function changing from 2nd to 3rd gear shift mode 1 2 3 7 1 2 3 50D9CD49 8 Horn By pressing position the horn sounds and by releasing the horn stops Sou...

Page 83: ...F ON 35D9AOM18 This switch turn ON the strobe light 1 11 10 When engine running the low rpm of engine increase or decrease by 25 rpm by operating this switch Engine low rpm returns to normal value whe...

Page 84: ...1 MULTI FUNCTION SWITCH 16 O J 73033CD29 Turning switch This switch is used to warn or signal the turning direction of the truck to other vehicles or equipment Push the lever up for turning left pull...

Page 85: ...ire SCR cleaning Refer to the page 3 14 for details This switch can be move to the manual SCR cleaning position only when the safety button is pulled to backward Also this switch return to the OFF pos...

Page 86: ...according to set up interval and time of the cooling fan reverse mode Refer to page 3 21 1 to set of the cluster OFF Only forward rotation is possible MANUAL The fan rotates reverse only while pressi...

Page 87: ...tor lever Inching pedal Accelerator pedal Brake pedal Lift lever Tilt lever 3 spool lever opt 4 spool lever opt 5 spool lever opt 7 CONTROL DEVICE LIFT LEVER 1 1 2 3 50D9CD12 Tilt forward Tilt backwar...

Page 88: ...FORK POSITIONER FORK POSITIONER SYNCHRONIZER TYPE 4 50D9CD19 LH MOVEMENT Push the lever forward to move the left hand for the side shift RH MOVEMENT Pull the lever backward to move the right hand for...

Page 89: ...g axle will operate the steering function Turning the steering wheel left the truck moves to the left side and turning it right the truck moves to the right side STEERING WHEEL 6 1 2 110D9CD33 This le...

Page 90: ...lifting up or putting down loads Do not put your foot on the inching pedal or brake pedal unless using it 1 INCHING PEDAL 9 160D7ECD34 By pulling down the lever the wheel is adjustable to tilt By pul...

Page 91: ...or pleasant operation against outside temperature and defrost on window glass 8 AIR CONDITIONER AND HEATER 110D9CD90 AIR CONDITIONER BUTTON When you push this button air conditioner system is operated...

Page 92: ...ot lamp OFF The air circulates in the cab The pilot lamp is turned ON when the button is pushed Check out the fresh air filter periodically to keep a good efficiency Change air occasionally when using...

Page 93: ...ket Use cigar lighter socket when you need emergency power Do not use the lighter exceeding 24 V 100 W Utilize the power of 12 V as your need and do not exceed power of 12 V 120 W 24V 1 2 1 2 1 73033C...

Page 94: ...ction knob 2 Power and volume button 3 Mode button select RADIO USB AUX 4 UP DOWN tuning button 5 Preset memory button 1 DISP ID3 v2 display 6 Preset memory button 2 SCN File scan 7 Preset memory butt...

Page 95: ...automatically return to the normal indication in 5 seconds after the last adjustment or when another function is activated Treble control To adjust the treble level first select the treble mode by pre...

Page 96: ...k socket USB Ear HP Indicator lamp Service socket USB Ear HP Mobile phone storage box 21093CD51 21093CD51A 1 Mobile phone can be stored when call by handsfree HANDSFREE OPTION 5 This socket is used to...

Page 97: ...Connect the jack cable when call by handsfree Use the special adapter when jack cable is not interchangeable Check the jack type of mobile phone before use This lamp is turned ON when the handsfree mo...

Page 98: ...lect HYUNDAI and set connect with Bluetooth on the mobile phone Default password 0000 The Bluetooth pairing is made the LCD screen shows CONNECTED Once the Bluetooth pairing is made they will be autom...

Page 99: ...or handsfree ON or OFF This switch is turned to right the handsfree volume is increased over 7 steps If it is turned to left volume will be decreased This switch adjust the audio volume when selected...

Page 100: ...urn a station of higher frequency and the next song of the MP3 Turn a station of lower frequency and the previous song of the MP3 Mute button Short press this button to mute or cancel the mute silence...

Page 101: ...d Radio handsfree You can make a call to external worker without holding the radio by hand The radio is not installed to the machine 55I3CD31H Talk button The call is connected while pressing this but...

Page 102: ...downwards up to 7 swivels left and right up to 15 7 50D9CD211 No Symbol Name Description 1 LEFT Move the Menu left Lower the value 2 MENU ENTER Enter the OSD menu Choose the menu 3 RIGHT Move the Men...

Page 103: ...0D9CD204K Display one camera image on screen Press left or right key to change the camera channel Display two camera images on screen Press left or right key to change the camera channel Display four...

Page 104: ...etting Language 2 3 4 50D9CD205 50D9CD207 50D9CD209 50D9CD206 50D9CD208 50D9CD210 Depending on the gear state forward backward camera channel is switched automatically Adjust the display brightness Se...

Page 105: ...c oil may be hot or under pressure When inspecting a lift truck wear safety Leaking hydraulic oil may be hot or under pressure When inspecting a lift truck wear safety glasses and do not check for lea...

Page 106: ...ers and indicator lights Service brakes inching pedal and parking brakes Hydraulic controls lift tilt and auxiliary If installed Accelerator pedal Gear selector lever Steering system Lift mechanism an...

Page 107: ...the level and leakage of coolant engine oil hydraulic oil and fuel Check regularly the lubrication and fill Grease daily all lubrication points Tighten bolts Warm up the truck fully before operation...

Page 108: ...a safe distance while refueling safe distance while refueling D35AOM106 D35AOM106 Make sure that the fuel oil cans are kept Make sure that the fuel oil cans are kept cleaned and attached safety indica...

Page 109: ...lift truck before operating at the start of each shift Before putting your truck to Inspect your lift truck before operating at the start of each shift Before putting your truck to use check the oper...

Page 110: ...for your truck The numbers on the inspection chart show the order of inspection These numbers correspond to the check item numbers given on the next pages Hang a caution sign on the truck for example...

Page 111: ...o explode causing serious injury or damage The tires and rims should always be serviced or changed by trained personnel damage The tires and rims should always be serviced or changed by trained person...

Page 112: ...ore adding water At the operating temperature the engine cooling water is at high temperature and pressure At the operating temperature the engine cooling water is at high temperature and pressure so...

Page 113: ...OK NOT OK 120096MA42 120096MA43 2609A6MA47 NOT OK INSPECTION OF COOLING FAN INSPECTION OF COOLING FAN Personal injury can result from a fan blade fail Personal injury can result from a fan blade fail...

Page 114: ...K PREFILTER CHECK PREFILTER 9 9 Bowl Drain valve Open Close 2907A6MI20 Drain valve Bowl Open Close 50D93CD15 Gauge l U S gal Mast spec Lower limit 268 71 Simplex Upper limit 285 75 Triplex CHECK CHECK...

Page 115: ...e wiper will be activated 2 3 times Check the quantity of washer liquid in the tank If the level of Check the quantity of washer liquid in the tank If the level of the washer liquid is LOW add the was...

Page 116: ...fficiency 1 1 160D7OM11 5 8 B D E F A C Forward Backward adjustment Forward Backward adjustment slide adjustment slide adjustment Pull lever A to adjust seat forward or backward Upward Downward adjust...

Page 117: ...controls function All controls are in neutral or other correct position The truck has received its daily inspection and ready and safe to operate Put the gear selector lever in the NEUTRAL position be...

Page 118: ...fe Let the engine run until the normal operating temperature is reached Then operate the controls and check all gauges and warning indicators to be sure they are functioning properly Stop the engine a...

Page 119: ...emain ON 1 2 3 7 STARTING AND STOPPING THE ENGINE 7 STARTING AND STOPPING THE ENGINE 1 1 1 3 2 Gear selector lever Parking brake switch 180D9OP04 STARTING ENGINE IN NORMAL TEMPER STARTING ENGINE IN NO...

Page 120: ...starting the engine Travelling the machine or operation of the attachments could be caused shut down of the engine In the event of the winter season the fuel oil happens WAX from 6 In the event of th...

Page 121: ...em as required as required Check engine exhaust color 5 Check fuel tank level 6 Colorless light blue Black White Exhaust gas color Criteria OK Check for incomplete combustion Check for oil leakage If...

Page 122: ...t and turn the adjust nut Equalize tension on the lift chain Do not put hands into the mast Do not put hands into the mast SEAT BELT WARNING LAMP ENGINE CHECK WARNING LAMP FUEL LOW LEVEL WARNING LAMP...

Page 123: ...it has cooled down engine life may be greatly has cooled down engine life may be greatly shortened Consequently do not abruptly shortened Consequently do not abruptly stop the engine apart from an eme...

Page 124: ...y and tilt the mast forward to the stroke end to relieve hydraulic pressure Do not leave hydraulic pressure relieved for Do not leave hydraulic pressure relieved for more than 30 seconds more than 30...

Page 125: ...ound and floor conditions grade speed loading dynamic and static forces and the judgement exercised by the operator speed loading dynamic and static forces and the judgement exercised by the operator...

Page 126: ...her you depress the inching pedal the more the driving clutch slips reducing travel motion With the inching pedal fully depressed the brakes fully engage You operate the inching pedal with your left f...

Page 127: ...o move the truck Changing direction and speed Changing direction and speed The gear selector lever is designed for the mounting on the left side of the steering column The positions speeds 1 to 3 are...

Page 128: ...ng does not function with engine OFF Steering does not function with engine OFF Precautions when driving Precautions when driving If the monitor warning lamp lights up put the gear selector lever in t...

Page 129: ...the truck Stopping the truck Press the brake pedal to stop the truck Put the gear selector lever in the neutral position Press the parking brake switch ON 6 6 Gear selector lever Parking brake switch...

Page 130: ...key Checks after the engine stopped Checks after the engine stopped Check the leakage of oil and water the work equipment and the exterior of the truck Refill the fuel tank Remove any debris inside of...

Page 131: ...ection to the operator from falling objects but cannot protect against every possible impact Therefore it should not be considered a substitute for good judgement and care in loading handling storage...

Page 132: ...gear state It makes the brake oil overheated due to excessive brake operation It makes the brake oil overheated due to excessive brake operation PRACTICE SAFE OPERATION EVERY TIME YOU USE YOUR TRUCK P...

Page 133: ...ised except to pick up or deposit a load over a rack or stack Slack chains mean rail or carriage hang up Raise the mast before you move If the mast Slack chains mean rail or carriage hang up Raise the...

Page 134: ...de easier Unlock the fork locking pins Position the forks by pushing them away from you Secure the fork locking pins 2 2 160D7OM134 LOAD ON FORKS LOAD ON FORKS Do not elevate the load with one fork Lo...

Page 135: ...ver possible Use special care when handling and traveling with long high or wide loads to avoid losing the load striking bystanders or obstructions or tipping the truck Watch clearances around the tru...

Page 136: ...than the load move the tips partially under the load without extending beyond the load Raise the load to clear the ground Back out several inches or whatever distance is necessary then set the load d...

Page 137: ...ther lift the load high enough to clear the top of the stack Slowly move the load into position Use care not to damage or move adjacent loads When the load is aligned with the stack beneath it tilt th...

Page 138: ...ad down and move forward until the front face of the forks contacts the load Be careful that the fork tips now clear the adjacent load or material behind the load being moved Raise the load from the s...

Page 139: ...THE TRUCK UNATTENDED UNATTENDED Tilt the mast forward until the forks are level and flat on the ground Let the engine run at idle speed Turn the start switch to the OFF position and remove the key Bl...

Page 140: ...rt distance once a month so that a new oil film will be coated over movable parts and component surfaces Remove and storage the battery at the same time The above operations should be performed in the...

Page 141: ...k and the loading dock Ensure that the transporter cannot move by applying the brake and putting blocks under the wheels Put the gear selector lever in the NEUTRAL position Fix the loading ramps secur...

Page 142: ...ist the truck Use long wire rope and stay to keep the distance with the machine as it should avoid touching with the truck body Put a rubber plate where the wire rope contact with the truck s body to...

Page 143: ...bled truck about 300 mm 12 in from the floor or ground Secure the carriage with a chain Obtain another lift truck of equal or larger size carrying a partial load for traction Check that the counterwei...

Page 144: ...move and cause injury or death to personnel near it injury or death to personnel near it Park the disabled truck in authorized areas only Fully lower the forks to the floor put the gear selector lever...

Page 145: ...ATTERIES EMIT EXPLOSIVE GAS Do not smoke or have open flames or sparks in BATTERIES EMIT EXPLOSIVE GAS Do not smoke or have open flames or sparks in battery charging areas or near batteries An explosi...

Page 146: ...ts that move Do not touch hot manifolds that can cause sever burns Start the engine on the jumper vehicle umper vehicle and run the engine at a moderate speed for a minimum of five minutes Start the e...

Page 147: ...ments and repairs made to correct any unsafe condition In addition to the operator s daily inspection HYUNDAI recommends that the owner set up and follow a periodic planned maintenance PM and inspecti...

Page 148: ...ts and in special work areas where protection is necessary and required Properly ventilate work area vent exhaust fumes and keep shop clean and floors dry Avoid fire hazards and have fire protection e...

Page 149: ...s not developed to the extent that it would create a hazard When working on the hydraulic system be sure the engine is turned off mast is in the fully lowered position and hydraulic pressure is reliev...

Page 150: ...dures Always use genuine HYUNDAI or HYUNDAI approved parts When removing tires follow industry safety practices Most importantly deflate pneumatic tires completely prior to removal Following assembly...

Page 151: ...L OPERATION Eight hour material handling mostly in buildings or in clean open air on clean paved surfaces SEVERE OPERATION SEVERE OPERATION Prolonged operating hours or constant usage EXTREME OPERATIO...

Page 152: ...il Remove the dust or water around the inlet of oil tank before supplying oil Drain oil when the temperature of oil is warm Do not repair anything while operating the engine Stop the engine when you f...

Page 153: ...nder hose Every 1 to 2 years 7 Tilt cylinder hose Every 1 to 2 years 8 Side shift cylinder hose Every 1 to 2 years 9 Brake hose or tube Every 1 to 2 years 10 Brake reservoir tank tube Every 2 to 4 yea...

Page 154: ...rque converter 11 Engine 12 Steering cylinder 13 Hydraulic pump 14 Steering axle 15 Rear wheel 16 Air cleaner 17 Counterweight 18 Radiator 19 Seat 20 Cabin 21 Steering wheel 22 Muffler 23 Propeller sh...

Page 155: ...ng plates and decals Condition of tires and wheels Air pressure Lift chain and fastener Carriage or attachment and forks Fuel level Engine oil level Coolant level Radiator reservoir tank Fan belt tens...

Page 156: ...Lubricate Check Lubricate Check Lubricate 7 43 7 45 7 49 7 25 7 25 7 37 7 55 7 55 7 55 7 55 7 55 7 55 7 55 7 55 7 55 7 55 7 55 7 55 Check items Service Remarks Mast mounting bolt Battery Engine oil fi...

Page 157: ...filter 2EA Engine lubrication system Engine oil Engine oil filter Engine cooling system Coolant Radiator Engine air intake and exhaust system Air cleaner element DEF AdBlue level Hydraulic tank Hydrau...

Page 158: ...r drain plug to avoid injury by unexpected spouting of high temperature fluid or gas Open the cap slowly to relieve pressure Always keep the surface of control instrument panels clean in case of damag...

Page 159: ...1 31 Air conditioner filter outer Check Clean 1 500 Hours or 3 monthly 7 Fuel filter element Replace 2 12 Radiator surge tank cap Check 1 17 Mast mounting bolt Check Tight 4 17 Drive axle mounting bo...

Page 160: ...n and any safety devices are in place undamaged and attached securely Check the cabin for damage Be sure that it is properly positioned and all mounting fasteners are in place and tight LOAD HANDLING...

Page 161: ...0 mm 4 in wide by 600 mm 24 in long with parallel sides on the blade of the fork with the 100 mm 4 in surface against the blade Put a 600 mm 24 in carpenter s square on the top of the block and agains...

Page 162: ...ad of the tire not form the side Use a long handled gauge to keep your body away from handled gauge to keep your body away from the side If tires are low do not operate and the side If tires are low d...

Page 163: ...c wirings can be easily performed It is recommended that the service requiring tilting cabin must be carefully performed with a skilled service man Tilting and returning cabin Tilting and returning ca...

Page 164: ...unction while the power is ON or engine is running 250D9MI64 53 4 250D9MI68A HAND PUMP 20mm Reservior tank Cap Full Drain 250D7EMI67 Replacement of hydraulic oil for hand pump Open upper cap and fill...

Page 165: ...oil level is in the normal range normal range Normal Engine oil fill Dipstick Drain pan plug REPLACEMENT OF ENGINE OIL AND OIL REPLACEMENT OF ENGINE OIL AND OIL FILTER FILTER Operate the engine until...

Page 166: ...filter head Mechanical over tightening may distort the Mechanical over tightening may distort the threads or damage the filter element seal threads or damage the filter element seal 7 Clean and inspec...

Page 167: ...et of surge tank cap when it is damaged Do not remove the surge tank cap from a hot Do not remove the surge tank cap from a hot engine Wait until the coolant temperature is engine Wait until the coola...

Page 168: ...eeze If in doubt contact your local authorities for If in doubt contact your local authorities for guidance as to proper handing of used guidance as to proper handing of used antifreeze antifreeze Wai...

Page 169: ...If the water being drained is still dirty the system must be flushed again until the water system must be flushed again until the water is clean is clean OFF 250D9MI10 250D9MI38 250D9MI10 The system...

Page 170: ...stem 250D9MI22 NOT OK 250D9MI11 Install the surge tank cap Operate the engine until it reaches a temperature 80 C 176 F and check for coolant leaks Check the coolant level again to make sure the syste...

Page 171: ...m bottle and replace cap immediately Do not touch the pads on the end of the strip Discard kit if nitrite test pads of unused strips have turned brown Dip strip for 1 second in coolant sample remove a...

Page 172: ...ent coolant filter change interval Normal Normal Continue to replace the coolant filter at your normal interval Below normal Below normal Replace the coolant filter and add 1 pint of additive per each...

Page 173: ...e to broken fins which can cause the engine to overheat refer to the manufacturer s overheat refer to the manufacturer s replacement procedures replacement procedures Visually inspect the radiator for...

Page 174: ...loose rivets and bent or Check for cracks loose rivets and bent or loose blades loose blades Check the fan to make sure it is securely Check the fan to make sure it is securely mounted Tighten the cap...

Page 175: ...with the spring case stop is still in contact with the spring case stop the tensioner MUST be replace stop the tensioner MUST be replace Check the location of the drive belt on the belt tensioner pul...

Page 176: ...f the filter is needed If there is any dam age to the filter body gaskets or endplates do not clean or reuse the filter should be discard ed Always clean filters in a clean environment observe strict...

Page 177: ...ghtening can distort the threads as well as damage the filter element threads as well as damage the filter element seal or filter canister seal or filter canister It will be necessary to fill the 10 m...

Page 178: ...me the fuel system Turn the starting switch to ON but do not attempt to start the engine This will cause the ECM to operate the fuel lift pump through a priming cycle which lasts at least 30 seconds C...

Page 179: ...rom the aftertreatment DEF are removed from the aftertreatment DEF dosing unit they must be discarded and dosing unit they must be discarded and replaced regardless of condition replaced regardless of...

Page 180: ...lizing element 2 into the DEF filter cartridge 3 Insert the assembly into the aftertreatment DEF dosing unit Install and tighten the cap 1 A 27 mm wrench can be used to install and tighten the filter...

Page 181: ...nt B A B C 7709A6MI31 4 5 6 DEF AdBlue DEF AdBlue TANK TANK The DEF AdBlue tank level must be checked daily with DEF AdBlue level gauge It is unlawful to tamper with or remove any It is unlawful to ta...

Page 182: ...e base with a wet rag breather base Clean the base with a wet rag to prevent water from entering the crankcase to prevent water from entering the crankcase OK A C 7709A6MI32 7 8 9 10 Lubricate the bre...

Page 183: ...s in the illustration Stop the engine and then leave for about 5 minutes Check the oil level at the level gauge The level gauge is located on the left side of the hydraulic oil tank The sight gauge sh...

Page 184: ...resent in the oil air is entering the hydraulic system Inspect the suction hoses hydraulic system Inspect the suction hoses and hose clamps for leakage or damage and hose clamps for leakage or damage...

Page 185: ...the bolts 2 7 4 1 kgf m 19 5 29 7 lbf ft Air breather Bolt Element Air breather 22 22 1 2 3 4 5 250D9MA18 Rear frame IN OUT Line filter REPLACE THE ELEMENT OF THE BRAKE REPLACE THE ELEMENT OF THE BRA...

Page 186: ...order to keep tires in good shape Do not inflate tires using flammable gases or Do not inflate tires using flammable gases or alcohol injector alcohol injector This cause explosion or personal injury...

Page 187: ...e clean those Otherwise it may cause of permanent deformation Tread Valve Side wall Carcass Bead REPLACEMENT OF TIRE REPLACEMENT OF TIRE Disassembly reassembly replacement and Disassembly reassembly r...

Page 188: ...d tighten torque Front 33 37 kgf m 239 268 ibf ft Rear 60 65 kgf m 434 470 ibf ft 1 2 3 4 5 6 7 8 9 10 4 4 STORING TIRES AFTER REMOVAL STORING TIRES AFTER REMOVAL As a basic rule store the tires in a...

Page 189: ...the oil level must be lying in the zone HOT Insert the oil level gauge again and tighten it by clockwise rotation When checking press the parking brake When checking press the parking brake switch and...

Page 190: ...bout 1 3 to 1 2 turn Mount the drain plug of transmission after cleaning it Fill the oil through level gauge inlet and check if the oil is at the appropriate level The proper oil amount is 27 liters 7...

Page 191: ...g oil Air breather CHECK AND SUPPLYING AXLE OIL CHECK AND SUPPLYING AXLE OIL Move the truck to flat ground Open the axle air breather to relieve internal air pressure Air breather Remove the plug and...

Page 192: ...put the drain plug of planetary gear in parallel to the ground HORIZ OIL FILL LEVEL DRAIN Planetary gear If the oil level is below the plug hole supply oil through a plug hole When checking the oil l...

Page 193: ...nge interval interval Differential gear Planetary gear Fill oil level plug HORIZ OIL FILL LEVEL DRAIN CLEANING AXLE BREATHER CLEANING AXLE BREATHER Remove dust or debris around the breather Remove the...

Page 194: ...e Press the parking brake switch and fix front Press the parking brake switch and fix front and rear tires with blocks and rear tires with blocks Set the mast and forks in a stable position Set the ma...

Page 195: ...part of working device to extend the lubricating interval Mount the lip to be faced out side when Mount the lip to be faced out side when replace the dust seal replace the dust seal If it is assembled...

Page 196: ...nic control units ECU MCU TCU cluster etc Connect the earth ground lead of the welding equipment as close to the welding points as possible Do not weld or flame cut on pipes or tubes Do not weld or fl...

Page 197: ...110D9MI50 When using the air conditioner for a long time open the window once every one hour Be careful not to overcool the cab The cab is properly cooled if the operator feels cool when entering ther...

Page 198: ...as and contributes to global warming Do not release refrigerant into the environment Safety precautions Safety precautions Work on the air conditioning system must only be performed by a qualified ser...

Page 199: ...reful not to get the electrolyte in eyes Wash with clean water and go to the doctor if it Wash with clean water and go to the doctor if it enters the eyes enters the eyes 1 1 2 2 36070FW05 Recycle Rec...

Page 200: ...m the condition of the cables and replace confirm the condition of the cables and replace it when the cables possess any kind of it when the cables possess any kind of abnormal damages such as crackin...

Page 201: ...FDCU 15 A MP3 handsfree 10 A Monitor 20 A Aircon heater 15 A Seat heater 10 A Park solenoid 10 A Illumination lamp 15 A Head lamp 15 A Front work lamp 15 A Rear work lamp 15 A Wiper horn 15 A Fuel wa...

Page 202: ...y are properly mounted and working correctly Horn Horn Press the horn button to check horn function If the horn or any other part does not operate report the failure and have it repaired before the tr...

Page 203: ...load on a 15 grade Do not operate a lift truck if the service or parking brakes are not operating properly Do not operate a lift truck if the service or parking brakes are not operating properly 5 5 A...

Page 204: ...eave the truck according to When you have completed the operational tests park and leave the truck according to standard shut down procedure as described in section 5 of this manual Be sure to make a...

Page 205: ...ye protection and protective clothing when air cleaning Never point the air nozzle at anyone nozzle at anyone Air clean the mast assembly drive axle radiator from both counterweight and engine side en...

Page 206: ...DAI 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 1 1 2 2 Lift chain wear and replace...

Page 207: ...engine Check the cooling water level If it is low add more water Wear safety glasses and a face shield when using compressed air Never touch the surge Wear safety glasses and a face shield when using...

Page 208: ...can be readily started the next morning When the electrolyte level is low add distilled water in the morning before work instead of When the electrolyte level is low add distilled water in the morning...

Page 209: ...ine long life hydraulic oil ISO VG15 Conventional hydraulic oil 1 Grease Lithium base grease NLGI No 2 Fuel ASTM D975 No 2 Coolant DCA4 ASTM D6210 Mixture of 50 ethylene glycol base antifreeze and 50...

Page 210: ...15 ISO VG 46 ISO VG 68 ASTM D975 NO 1 ASTM D975 NO 2 NLGI NO 1 NLGI NO 2 Ethylene glycol base permanent type 50 50 50 30 20 10 0 10 20 30 40 58 22 4 14 32 50 68 86 104 Ethyleneglycolbasepermanenttype...

Page 211: ...T mm in 2450 250 110 96 5 9 8 4 3 Mast Tilt angle forward backward C C degree 12 10 Max height K mm ft in 5830 19 2 Min height M mm ft in 3870 12 8 Body Travel speed Unload km h 31 5 Gradeability Load...

Page 212: ...Piston displacement cc cu in 8900 543 Compression ratio 17 8 1 Rated gross horse power hp rpm 278 2200 Maximum gross torque at rpm kgf m rpm 124 1500 Engine oil quantity U S gal 20 5 3 Dry weight kg...

Page 213: ...044 3 0 854 Axle Type Front wheel drive type fixed location Gear ratio 17 52 1 Gear Ring Pinion gear type Wheels Q ty FR RR Double 4 2 Front drive 14 00 24 32 PR Rear steer 14 00 24 32 PR Brakes Trave...

Page 214: ...7 Torque converter mounting bolt M10 1 5 6 9 1 4 49 9 10 8 Drive axle mounting bolt nut M30 3 5 115 10 831 72 9 Steering axle mounting bolt nut M48 5 0 199 30 1440 217 10 Front wheel mounting nut M18...

Page 215: ...m Fuel injection pump or nozzle defec tive Starting motor rotates slowly Engine compression insufficient Valve clearance out of adjustment Addfuel Repair Replace See Electrical system Adjust clearance...

Page 216: ...left in ON position Caution lamp defective Caution lamp switch defective Replace Replace Faulty wiring Glow plug damaged Check and repair Replace Faulty wiring Insufficient battery voltage Check and...

Page 217: ...ced in neutral position If so replace clutch plate Bearing worn or seized Disassemble check and replace 2 Noise operation 2 Noise operation 1 Torque converter Cavitation produced Change oil replace pa...

Page 218: ...dd oil Check joints and pipes If necessary retighten joint or replace packing Check and replace Check oil pressure If necessary rep lace pump Check spring tension If necessary replace Disassemble chec...

Page 219: ...ts and replace Probable cause Probable cause Remedy Remedy 5 Power is not transmitted 5 Power is not transmitted 1 Torque converter 2 Transmission Clutch plate damaged Low oil level Oil pump driving s...

Page 220: ...il leaks from a crack Disassemble and check for wear of seal lips and mating sliding surfaces pump boss coupling etc Replace oil seal pump boss coupl ing etc Check and retighten or replace pack ing Ch...

Page 221: ...ucks air Valve Faulty Unbalance oil pressure Piping Pipe from pump to power steering dented or clogged Insufficient air bleeding Flow control valve orifice clogged Piping Pipe from tank to pipe dented...

Page 222: ...Hydraulic system clogged Adjust tire pressure Adjust Repair by polishing or replace Adjust or replace Clean Repair and add oil Bleed air Replace Repair or replace Clean Probable cause Probable cause R...

Page 223: ...m joint or hose Excessive restriction of oil flow on pump suction side Relief valve fails to keep specified pressure Poor sealing inside cylinder High hydraulic oil viscosity Mast fails to move smooth...

Page 224: ...moothly Deformed masts or carriage Faulty hydraulic equipment Damaged load and side rollers Unequal chain tension between LH RH sides LH RH mast inclination angles are unequal Mast assembly is twisted...

Page 225: ...asons such as overloading glancing blows against walls and objects and picking up load unevenly Difference in fork tip height If the measured value exceeds the allowance replace fork Fatigue Fatigue f...

Page 226: ...elector lever at NEUTRAL Set gear selector lever at NEUTRAL IDLING IDLING After warming up engine run at idling Check that engine maintains steady smooth rotation without gasping abnormal noise abnorm...

Page 227: ...LTER FUEL FILTER 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 r...

Page 228: ...10 3 FAN FAN Move fan backwards and forwards by hand to check for looseness Tighten mounting bolt with a spanner Crack 160D7TA11 7 7...

Page 229: ...erates and oil comes to reverse clutch thus the truck will run backward OIL LEAKAGE OIL LEAKAGE Check that there is no oil leakage from torque converter transmission or control valve If oil oozes out...

Page 230: ...so that pedal angle is H voltage 1 0 1V Pedal angle H 35 When fully pedaled voltage is controlled to 3 5 0 1 V Adjust bolt 3 so that brake pedal interconnects with inching pedal at inching pedal strok...

Page 231: ...SIDE RING Check rim side ring for deformation or cracks Check visually or use crack detection method Rear rim connecting nut torque SEE SECTION 8 SPECIFICATIONS 3 3 D35ATA15 STEERING AXLE STEERING AXL...

Page 232: ...ring wheel If play is too large adjust at gearbox Test steering wheel play with engine at idling 30 60mm 1 2 2 4 in 1 1 2 2 STEERING AXLE STEERING AXLE Put camber gauge in contact with hub and measure...