Hyundai 110D-9 User manual

CONTENTS
CONTENTS
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. SAFETY HINTS
1. SAFETY HINTS
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
2. OPERATING HAZARDS
2. OPERATING HAZARDS
1. Loose loads -------------------------------------------------------------------------------------------------------------------- 2-1
2. Long and wide loads ----------------------------------------------------------------------------------------------------- 2-2
3. Rear swing --------------------------------------------------------------------------------------------------------------------- 2-2
4. Low overhead clearance ----------------------------------------------------------------------------------------------- 2-3
5. Fast turns and high loads ---------------------------------------------------------------------------------------------- 2-3
6. Right angle stacking ------------------------------------------------------------------------------------------------------ 2-4
7. Chain slack --------------------------------------------------------------------------------------------------------------------- 2-4
8. Pallets and skids ------------------------------------------------------------------------------------------------------------ 2-5
9. Caution for electrical lines --------------------------------------------------------------------------------------------- 2-5

10. Lifting loads -------------------------------------------------------------------------------------------------------------------- 2-6
11. Side shift ------------------------------------------------------------------------------------------------------------------------- 2-7
12. Fork positioner
--------------------------------------------------------------------------------------------------------------- 2-8
13. Solid tire -------------------------------------------------------------------------------------------------------------------------- 2-8
3. KNOW YOUR TRUCK
3. KNOW YOUR TRUCK
1. General locations ----------------------------------------------------------------------------------------------------------- 3-1
2. Name plate and safety warning decal ------------------------------------------------------------------------- 3-2
3. Cab devices ------------------------------------------------------------------------------------------------------------------- 3-4
4. Cluster ---------------------------------------------------------------------------------------------------------------------------- 3-5
5. Transmission message indicator --------------------------------------------------------------------------------- 3-27
6. Switches ------------------------------------------------------------------------------------------------------------------------- 3-30
7. Control device ---------------------------------------------------------------------------------------------------------------- 3-37
8. Air conditioner and heater --------------------------------------------------------------------------------------------- 3-41
9. Others ----------------------------------------------------------------------------------------------------------------------------- 3-43
4. OPERATOR MAINTENANCE AND CARE
4. OPERATOR MAINTENANCE AND CARE
1. Daily safety inspection --------------------------------------------------------------------------------------------------- 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 -------------------------------------------------------------------------------------------------- 5-2
3. Check before starting engine ---------------------------------------------------------------------------------------- 5-3
4. Seat adjustment ------------------------------------------------------------------------------------------------------------- 5-8
5. Starting from a safe condition --------------------------------------------------------------------------------------- 5-9
6. General starting and operating tips ------------------------------------------------------------------------------ 5-10
7. Starting and stopping the engine --------------------------------------------------------------------------------- 5-11
8. Warming-up operation --------------------------------------------------------------------------------------------------- 5-16
9. Levers and pedals ---------------------------------------------------------------------------------------------------------- 5-17
10. Traveling of the truck ------------------------------------------------------------------------------------------------------ 5-19
11. Operating safely ------------------------------------------------------------------------------------------------------------- 5-23
12. Load handling ---------------------------------------------------------------------------------------------------------------- 5-25
13. Shut down procedure ---------------------------------------------------------------------------------------------------- 5-31
14. Storage --------------------------------------------------------------------------------------------------------------------------- 5-32
15. Transport ------------------------------------------------------------------------------------------------------------------------- 5-33
16. Loading and unloading by crane ---------------------------------------------------------------------------------- 5-34

6. EMERGENCY STARTING AND TOWING
6. EMERGENCY STARTING AND TOWING
1. How to tow a disabled truck ------------------------------------------------------------------------------------------ 6-1
2. Parking brake release ---------------------------------------------------------------------------------------------------- 6-3
3. How to use battery jumper cables -------------------------------------------------------------------------------- 6-4
7. PLANNED MAINTENANCE AND LUBRICATION
7. PLANNED MAINTENANCE AND LUBRICATION
1. Introduction -------------------------------------------------------------------------------------------------------------------- 7-1
2. Safe maintenance practices ---------------------------------------------------------------------------------------- 7-2
3. Instructions before maintenance --------------------------------------------------------------------------------- 7-5
4. Planned maintenance intervals ----------------------------------------------------------------------------------- 7-8
5. Maintenance chart -------------------------------------------------------------------------------------------------------- 7-13
6. How to perform planned maintenance ----------------------------------------------------------------------- 7-15
7. Service instruction ------------------------------------------------------------------------------------------------------ 7-20
8. Electrical system ---------------------------------------------------------------------------------------------------------- 7-47
9. Air conditioner and heater ---------------------------------------------------------------------------------------- 7-48
10. Replacement and check ------------------------------------------------------------------------------------------- 7-49
11. Handling truck in extremely hot places ------------------------------------------------------------------ 7-59
12. Cold weather operation --------------------------------------------------------------------------------------------- 7-60
13. Recommendation table for lubricants --------------------------------------------------------------------- 7-61
14. Fuel and lubricants ----------------------------------------------------------------------------------------------------- 7-62
8. SPECIFICATIONS
8. SPECIFICATIONS
1. Specification table ----------------------------------------------------------------------------------------------------------- 8-1
2. Specification for major components ------------------------------------------------------------------------------ 8-2
3. Tightening torque ------------------------------------------------------------------------------------------------------------ 8-6
9. TROUBLESHOOTING
9. TROUBLESHOOTING
1. Engine system ---------------------------------------------------------------------------------------------------------------- 9-1
2. Electrical system ------------------------------------------------------------------------------------------------------------- 9-2
3. Torque flow system -------------------------------------------------------------------------------------------------------- 9-3
4. Steering system -------------------------------------------------------------------------------------------------------------- 9-7
5. Brake system ------------------------------------------------------------------------------------------------------------------ 9-8
6. Hydraulic system ------------------------------------------------------------------------------------------------------------ 9-9
7. Mast and fork ------------------------------------------------------------------------------------------------------------------ 9-10
10. TESTING AND ADJUSTING
10. TESTING AND ADJUSTING
1. Engine system ---------------------------------------------------------------------------------------------------------------- 10-1
2. Drive system ------------------------------------------------------------------------------------------------------------------- 10-4
3. Travel system ------------------------------------------------------------------------------------------------------------------ 10-6
4. Steering system -------------------------------------------------------------------------------------------------------------- 10-7

0-1
Lift trucks are specialized trucks with unique operating characteristics, designed to perform a specific
job. Their function and operation is not like a car or ordinary truck. They require specific instructions
and rules for safe operation and maintenance.
Safe operation of lift trucks is of primary importance to HYUNDAI.
Our experience with lift truck accidents has shown that when accidents happen and people are killed or
injured, the causes are:
 Operator not properly trained
 Operator not experienced with lift truck operation
 Basic safety rules not followed
 Lift truck not maintained in safe operating condition
For these reasons, HYUNDAI wants you to know about the safe operation and correct maintenance of
your lift truck.
This manual is designed to help you operate your lift truck safely.
This manual shows and tells you about safety inspections and the important general safety rules and
hazards of lift truck operation. It describes the special components and features of the truck and
explains their function. The correct operating procedures are shown and explained. Illustrations and
important safety messages are included for clear understanding. A section on maintenance and
lubrication is included for the lift truck mechanic.
The operator's manual is not a training manual. It is a guide to help trained and authorized operators
safety operate their lift truck by emphasizing and illustrating the correct procedures. However, it cannot
cover every possible situation that may result in an accident. You must watch for hazards in your 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 is maintained in a safe condition. Do not operate a damaged or
malfunctioning truck. Practice safe operation every time you use your lift truck. Let's join together to set
high standards in safety.
Remember, before you start operating this lift truck, be sure you understand all driving procedures. It is
your responsibility, and it is important to you and your family, to operate your lift truck safely and
efficiently.
Be aware that the Federal Occupational Safety and Health Act (OSHA) and state laws require
that operators be completely trained in the safe operation of lift trucks; It is also an (OSHA)
requirement that a truck inspection be performed before every shift. If you need training in
operating or inspecting your lift truck, ask your supervisor.
HYUNDAI lift trucks are built to take hard work, but not abuse. They are built to be dependable, but they
are only as safe and efficient as the operator and the persons responsible for maintaining them. Do not
make any repairs to this truck unless you have been trained in safe lift truck repair procedures and are
authorized by your employer.
This manual describes procedures for operation, handling, lubrication, maintenance, checking and
adjustment. It will help the operator realize peak performance through effective, economical and safe
truck operation.
A MESSAGE TO HYUNDAI LIFT TRUCK OPERATORS

0-2
HYUNDAI welcomes you to the growing group of professionals who own, operate and maintain
HYUNDAI lift trucks. We take pride in the long tradition of quality products and superior value the
HYUNDAI name represents. This manual familiarizes you with safety, operating, and maintenance
information about your new lift truck. It has been specially prepared to help you use and maintain your
HYUNDAI lift truck in a safe and correct manner.
Your HYUNDAI lift truck has been designed and built to be as safe and efficient as today's technology
can make it. As manufactured, for some models, it meets all the applicable mandatory requirements of
ANSI B56.1-1988 Safety Standard for Powered Industrial Trucks. Some trucks are also furnished with
equipment to help you operate safety; for example, load back rest, parking brake and horn are standard
equipment.
Safe, productive operation of a lift truck requires both skill and knowledge on the part of the operator.
The operator must know, understand, and practice the safety rules and safe driving and load handling
techniques described in this manual. To develop the skill required, the operator must become familiar
with the construction and features of the lift truck and how they function, the operator must understand
its capabilities and limitations, and see that it is kept in a safe condition.
Routine Servicing and Maintenance
Regular maintenance and care of your lift truck is not only important for economy and utilization
reasons; it is essential for your safety. A faulty lift truck is a 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 of maintenance.
Operator Daily Inspection - Safety and Operating Checks
A lift truck should always be examined by the operator, before driving, to be sure it is safe to operate.
The importance of this procedure is emphasized in this manual with a brief illustrated review and later
with more detailed instructions. HYUNDAI dealers can supply copies of a helpful Drivers Daily
Checklist. It is an OSHA requirement.
Planned Maintenance
In addition to the daily operator inspection, HYUNDAI recommends that a planned maintenance and
safety inspection program(PM) be performed by a trained and authorized mechanic on a regular basis.
The PM will provide an opportunity to make a thorough inspection of the safety and operating condition
of your lift truck. Necessary adjustments and repairs can be done during the PM, which will increase
the lift or components and reduce unscheduled downtime and increase safety. The PM can be
scheduled to meet your particular application and lift truck usage.
The procedures for a periodic planned maintenance program that covers inspections, operational
checks, cleaning, lubrication, and minor adjustments are outlined in this manual. Your HYUNDAI dealer
is prepared to help you with a Planned Maintenance Program by trained service personnel who know
your lift truck and can keep it operating safely and efficiently.
Service Manual
In-depth service information for trained service personnel is found in Service Manual.
INTRODUCTION