CONTENTS

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

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

3. KNOW YOUR TRUCK

1. General locations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
2. Data/safety plate and decal - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2
3. Cab devices - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-4
4. Cluster - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-5
5. Transmission message indicator- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-16
6. Switches - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-20
 7. Control device - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-26
8. Air conditioner and heater - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-29
9. Others - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-31

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

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

1. How to tow a disabled truck - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
2. How to use battery jumper cables - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-3

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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-12
6. How to perform planned maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-14
7. Service instruction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
 8. Electrical system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-45
9. Air conditioner and heater - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-46
10. Replacement and check - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-47
11. Handling truck in extremely hot places - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-63
12. Cold weather operation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-64
13. Recommendation table for lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-65
14. Fuel and lubricants - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-66

8. SPECIFICATIONS
1. Specification table - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-1
2. Specification for major components - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-2
3. Tightening torque - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8-4

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

10. TESTING AND ADJUSTING

1. Engine system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-1
2. Drive system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-4
3. Travel system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-6
4. Steering system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10-7
 A MESSAGE TO HYUNDAI LIFT TRUCK OPERATORS

Lift trucks are specialized machines 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 machine 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
machine operation.

0-1
 INTRODUCTION

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
life of 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.

0-2
 HOW TO USE THIS MANUAL

This manual is a digest of essential information about the safe operation, the features and functions and
explains how to maintain your lift truck. This manual is organized into nine major parts:
Section 1. Safety hints, reviews and illustrates accepted practices for safe operation of a lift truck.
Section 2. Operating Hazards, warns of conditions that could cause damage to the truck or injury to
the operator or other personnel.
Section 3. Know Your Truck, describes the major operating components, systems, controls, and other
features of your truck and tells how they function.
Section 4. Operator Maintenance and Care, presents details on how to perform the operator's daily
safety inspection and refuel the lift truck.
Section 5. Starting and Operating Procedures, discusses specific instructions on the safe, efficient
operation of your lift truck.
Section 6. Emergency Starting and Towing, gives instructions for towing your truck in an emergency
and for using battery jumper cables to start your truck in an emergency.
Section 7. Planned Maintenance and Lubrication, describes the PM (Planed Maintenance) program.
Section 8. Specifications, provides reference information and data on features, components, and
maintenance items.
Section 9. Troubleshooting, provides trouble symptoms, causes and methods of remedy.
Section10. Testing and Adjusting, gives instructions for testing and adjusting.

※T The descriptions and specifications included in this manual were in effect at the time of printing.
HYUNDAI reserves the right to make improvements and changes in specifications or design, without
notice and without incurring obligation. Please check with your authorized HYUNDAI dealer for
information on possible updates or revisions.
The examples, illustrations, and explanations in this manual should help you improve your skill and
knowledge as a professional lift truck operator and take full advantage of the capabilities and safety
features of your new lift truck.
The first section of the manual is devoted to a review, with illustrations and brief messages, of general
safety rules and the major operating hazards you can encounter while operating a lift truck. Next, you
will find description's of the components of your specific lift truck model and how the instruments,
gauges, and controls operate. Then, you will find a discussion of safe and efficient operating
procedures, followed by instruction's on how to tow a disabled lift truck. The later sections of the manual
are devoted to maintenance and truck specifications.
Take time to carefully read the Know Your Truck section. By acquiring a good basic understanding of
your truck's features, and how they function, you are better prepared to operate it both efficiently and
safely.
In Planned Maintenance, you will find essential information for correct servicing and periodic
maintenance of your truck, including charts with recommended maintenance intervals and component
capacities. Carefully follow these instructions and procedures.
Each major section has its own table of contents, so that you can find the various topics more easily.

0-3
We urge you to first carefully read the manual from cover to cover. Take time to read and understand
the information on general safety rules and operating hazards. Acquaint yourself with the various
procedures in this manual. Understand how all gauges, indicator lights, and controls function. Please
contact your authorized HYUNDAI dealer for the answers to any questions you may have about your lift
truck's features, operation, or manuals.
Operate your lift truck safely; careful driving is your responsibility.
Drive defensively and think about the safety of people who are working nearby. Know your truck's
capabilities 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 intended to be a permanently attached part of your lift truck. Keep it on the truck as a
ready reference for anyone who may drive or service it. If the truck you operate is not equipped with a
manual, ask your supervisor to obtain one and have it attached to the truck. And, remember, your
HYUNDAI dealer is pleased to answer any questions about the operation and maintenance of your lift
truck and will provide you with additional information should you require it.

※ Illustrations may differ from your truck, but they are applicable to your truck.

0-4
 EC REGULATION APPROVED

· Noise level (2000/14/EC and EN 12053) are as followings.

Model LWA(EU only) LPA

250D-7E 109 dB 77 dB

· The value of vibrations transmitted by the operator's seat are lower than standard value of
(2005/88/EC)

0-5
 SAFETY LABELS
1. LOCATION
Always keep these labels clean. If they are lost or damaged, attach them again or replace them with
a new label.

16,17, 18, 19 28

29

24 12

CABIN RCV LEVER DRIVE RH S/W VIEW A-A "VIEW" (RADIATOR TOP)

32
9 5 9 9 4 22
10

9 9
CABIN INSIDE - RH
9
15

9
9
13

9 9 9 3

11 7 CABIN INSIDE - LH 11

1 A 23 8 11 11 8 23 1

2 A 2

8 20 27 6 26 25 25 14 8 250D7EOM101

1 Logo 11 Hook 22 Load capacity

2 Warning-mast 12 Fan 23 Engine room
3 Temperature 13 Safety instruction(OPSS) 24 Start key
4 Radiator cap 14 ECU/TCU caution 25 Name
5 Fuel 15 Operator safety 26 Brake cooling oil
6 Hydraulic oil 16 Attach - lift/lower 27 Cab tilt(Up/Stop/Down)
7 Hand caution 17 Attach - tilt 28 Name plate
8 Tire pressure 18 Attach - s/shift, LH 29 UL label
9 Safety work 19 Attach - s/shift, RH 31 Air compressor
10 Accumulator 20 Tilt cabin warning 32 Starting procedure

0-6
2. DESCRIPTION
There are several specific warning labels on this machine please become familiarized with all warning
labels.
Replace any safety label that is damaged, or missing.
1) WARNING-MAST(ltem 2)
This warning label is positioned on the both
side of the mast.
Never stand or work under the raised
forks even if the hydraulic safety lock
lever is applied.
In case of working under the forks, it is
essential to support the carriage with
blocks.

25L7A0OM06

2) TEMPERATURE(Item 3)
This warning label is positioned on the top
side of engine hood over the radiator.
Coolant must be checked as specified in
the maintenance chart.

25L7A0OM10

3) Radiator cap (ltem 4)

This warning label is positioned on the top
side of the engine hood to warn the danger
or injury due to hot water which can be
spotted out from the radiator when operning
the radiator cap.
Never open the filler cap while engine 91FJ-00190

running or at high coolant temperature.

91FJ-00190

0-7
4) HAND CAUTION (Item 7)
This warning label is positioned on the top
side of mast.
It warns of the danger of injury from
movement between rails, chains,
sheaves, fork carriage, and other parts of
the mast assembly. Do not climb on or
reach into the mast. Personal injury will
result if any part of your body is put 35DEOM103
between moving parts of the mast.

5) TIRE (Item 8)
This label is positioned on near the rear
fender. (2 places of left and right respective-
ly)
Tire pressure must be checked in
92AT-00830
accordance with the maintenance chart.
kgf/cm PSI
Refer to page 5-3 for the regulated tire
air pressure(A and B). A B
25L7A0OM08

6) Hook (Item 11)

This warning label is positioned on the lifting
bracket of the upper counterweight (2
places respectively) and the top side of
mast.
Refer to page 5-33 for safe loading
procedures.

92FT-40640
180D7EOM102

7) Fan (ltem 12)

This warning label is positioned on the top
side of the radiator.
It warns of the danger or injury from
spinning fan blades when the engine is
running. Be sure that you keep your
hands, fingers, arms, and clothing away
from a spinning fan. Don't stand in line
with a spinning fan. Fan blades can D353AOM63
break at excessively high RPM and be
thrown out of the engine compartment.

0-8
8) SAFETY INSTRUCTION (Item 13) Truck for USA or equipped with *OPSS.
This warning label is positioned on the
inside of cabin door if the truck is for USA or SAFETY INSTRUCTIONS
equipped with *OPSS. This forklift equipped with an operator existence sensingsing
system per ASME/ISO 3691

This forklift is equipped with an operator Power travel movement 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.
existence sensing system per ASME/ISO The Forward/Reverse lever must be cycled through neutral with
the operator in the normal operating position to regain powered
3691. directional control.
Control of mast tilting, lifting and lowering is not possible through
(1) Powered travel movement of the truck operation of the appropriate control when the operator is not
in the normal position.

shall be possible only if the operator is in Please review Operator’s manual for safe operation of forklift.
92AW-00240

the normal operating position.

180D7EOM62
Transmission will automatically shift to
*OPSS : Operator Presence Sensing System
neutral upon the exiting of the operator.
(2) The forward/reverse lever must be cycled
through neutral with the operator in the
normal operating position to regain
powered direction control.
(3) Control of mast tilting, lifting and lowering
is not possible through operation of the
appropriate control when the operator is
not in the normal position.
※ Please review this manual for safe
operation of forklift.

9) ECU/TCU CAUTION (Item 14)

This warning label is located at beneath of
cabin door.
E/G ECU T/M TCU
※ Connector ①,, ②,, ③ and ④ should be
separated from ECU/TCU before any kind 1 2 3 4

of welding.

૳୦ୢ઩
ECU૕
TCU઩ছ










ಟ‫ٸ‬ഉࠜ
ंࠤ෇ਖਏૈ
1 2 3 4

Connector 1 2 3 4 Should be separated form ECU

and TUC before any kind of welding.
93HS-40280

180D7EOM91

0-9
10) OPERATOR SAFETY (item 15)
This warning label is positioned on the front
outside of overhead guard stay-LH.
1
① Refer to operator's manual in detail.
② Always buckle up the seat belt for safety
2
operation.
③ When the operator get off the machine,
always pull the parking brake lever so that 3
the machine can keep with stopping
condition. 4
④ The people should not pass through
under forks and other attachments which
are lifted or being lifted. 5
⑤ Do not jump down from the machine. It
can be caused that the operator have
severe injury or death in the event of a tip 6
over.
⑥ Outstretch the legs as widely as possible 7
and grasp firmly the steering handle.
⑦ Lean the body to the opposite direction in 25L7AOM09-1

order to avoid severe injury or death

when the machine is tipped over.
※ Refer to page 3-3 for details.

11) START PROCEDURE (item 32)

Start Procedure
This warning label is located on the right
1. Start ignition on.
side of the cabin inside. 2. Wait up to 4 seconds for grid heater operation in summer.
(45 seconds in winter)
(1) Start ignition on. 3. Start cranking.
(Tier 3 QSB is equipped with mechanical fuel lift pump.)
(2) Wait up to 4 seconds for grid heater 4. If engine still does not start, turn the Keyswitch to OFF position.
5. Loosen fuel supply line at the outlet of pre-filter.
operation in summer.
6. Do hand-priming repeatedly until air bubbles comes out from
(45 seconds in winter) fuel supply line completely.

(3) Start cranking. 7. Tighten fuel supply line to its origin position.
8. Recranking.
(Tier 3 QSB is equipped with mechanical 9. If the engine still would not start,
please contact the nearest HYUNDAI or Cummins dealers.
fuel lift pump.)
(4) If the engine still does not start, turn the 91LB-11170

keyswitch to OFF position.

(5) Loosen fuel supply line at the outlet of
pre-filter.
(6) Do hand-priming repeatedly until air bubbles comes out from fuel supply line completely.
(7) Tighten fuel supply line to its origin position.
(8) Recranking.
(9) If the engine still would not start, please contact the nearest HYUNDAI or Cummins dealers.

0-10
 GUIDE
1. DIRECTION
The directions of this truck indicate forward, Front
backward, right and left when truck is in the
travelling direction.

Left Right

Rear 250D7EOM01

2. SERIAL NUMBER
Inform following when you order parts or the truck is out of order.

1) TRUCK SERIAL NUMBER

It's shown on front of the right side frame.

160D7SM02

2) ENGINE SERIAL NUMBER

The numbers are located on the engine name
Engine serial No.
plate.

180D7EFW03

3. SYMBOLS
Important safety hint.
It indicates matters which can cause the great loss on the truck or the surroundings.
※ It indicates the useful information for operator.

0-11
 1. SAFETY HINTS
1. DAILY INSPECTION

At the beginning of each shift, inspect your truck

and fill out a check, maintenance and lubrication
table.
Check for damage and maintenance problems.
Have repairs made before you operate the truck.
Do not make repairs yourself. Lift truck
mechanics are trained professionals. They know
how to make repairs safely.

2507EOM02

1-1
2. DO'S AND DON'TS

Do watch for pedestrians.

D35AOM03

Do wear safety equipment when required.

D35AOM05

Don't mix drugs or alcohol with your job.

D35AOM02

Don't block safety or emergency equipment.

160D7OM04

Don't smoke in NO SMOKING areas or when refueling.

D35AOM06

1-2
 Don't operate the truck outdoors in rainy day.
ö Exclude the truck equipped cabin.

250D7OM07

Exhaust gas is dangerous.

Do not operate the truck at the inhouse, if possible.
Provide adequate ventilation when working in a closed space.

250D7OM08

1-3
3. SEAT BELTS

Always buckle up for the truck equipped

with safety belt.

160D7OM09

Seat belts can reduce injuries.

160D7OM11

1-4
4. NO RIDERS

1) The operator is the only one who should be

on a truck.

250D7EOM12

2) Never transport personnel on the forks of a

lift truck.

250D7EOM14

1-5
5. PEDESTRIANS

1) Watch where you are going. Look in the

direction of travel. Pedestrians may use the
same roadway you do. Sound your horn at
all intersections or blind spots.

250D7EOM05

2) Watch for people in your work area even if

your truck has warning lights or alarms.
People may not watch for you.

D35AOM14

3) Watch for people standing back, even when

you are parked.

250D7EOM06

1-6
6. OPERATOR PROTECTION

1) Stay inside the cabin.

2) Always keep your body within the confines of
the truck.
Do not operate truck without cabin or
overhead guard, unless condition prevent
use of it.

250D7EOM16

1-7
 7. FORK SAFETY

Never allow anyone to walk under raised forks.

D255OM17A

There is special equipment to raise people for

overhead work.
DO NOT USE LIFT TRUCKS.

250D7EOM14

Always lower the load slowly.

Raise and lower with mast vertical or tilted
slightly back(Never forward).

250D7EOM17

1-8
8. PINCH POINTS

Keep hands, feet and legs out of the

mast.

D255OM61

Don't use the mast as a ladder.

250D7EOM62

Never try to repair the mast, carriage,

chain, or attachment by yourself. Always
get a trained mechanic.

250D7EOM63

1-9
9. TRAVEL

1) Travel with the load near the floor/ground,

with mast tilted back to cradle the load
whenever possible.
Never lift or lower the load when the
truck is in motion.

250D7EOM18

2) 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.

250D7EOM25

3) Unstable loads are a hazard to you and to

your fellow workers. Always make certain
Wrong
that the load is well stacked and evenly
positioned across both forks. Never
attempt to lift a load with only one fork.

250D7EOM26

1-10
10. GRADES, RAMPS, SLOPES AND INCLINES

Never turn on a grade, either loaded or unloaded.

1) Unloaded-Forks downgrade

250D7EOM30

2) Loaded - Forks upgrade

250D7EOM33

1-11
11. TIP OVER

1) LATERAL TIP OVER

(1) Lateral tip over can occur with a combination
of speed and sharpness of turn. This
combination will exceed the stability of the
truck. This condition is even more likely with
an unloaded truck.
(2) With the load or mast raised, lateral tip over
can occur while turning and/or braking when
traveling in reverse or accelerating and
turning while traveling forward.
(3) Lateral tip over can occur loaded or
unloaded by turning on an incline or ramp. 250D7EOM38

2) LONGITUDINAL TIP OVER

(1) Longitudinal tip over can occur with
combination of overloading and load
elevated also with capacity load and
elevated. This combination will exceed the
stability of the truck. This condition is even
more likely with excessive forward tilt,
braking in forward travel or accelerating
rearward.
(2) Longitudinal tip over can occur by driving
with the load down slope on a steep grade.
250D7EOM39

Lateral and longitudinal tip over can occur if

the truck is driven over objects on the floor or
ground, off the edge of improved surfaces, or
into potholes in the road surface, or by running
into overhead objects or collisions.
An off dock type of tip over can occur if the
truck is steered too close to the dock edge,
driven off the edge of the dock or ramp, or if
the highway truck or trailer rolls away from the
dock or is driven away during loading.
The conditions listed above can be further
aggravated by overloading, excessive tilt,
or off center loads.
Lift truck tip over can cause serious injury
or death if the operator is trapped between
the truck and the ground.

1-12
3) WHAT TO DO IN CASE OF A TIP OVER
If your truck starts to tip over, Do not
jump.
Brace yourself as illustrated right.
3
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
4. Brace your feet.
Your chances for survival in a tip-over
are better if you stay with the truck, in
1 2
your seat.

D35AOM30

1-13
12. SURFACE AND CAPACITY

Avoid these conditions. They can cause a

truck to tip over or lose traction for braking or
driving.
Know the weight of your truck and load.
Especially when using elevators, Know
the capacity of the elevator you intend to
use. Do not overload. ICE
OIL SAND

MUD
GRAVEL

WEAK
FLOORS

250D7EOM40

TIPOVER
Seat belts can reduce injuries.
ALWAYS BUCKLE UP

160D7OM11

1-14
13. PARKING

1) Never park on a grade.

250D7EOM41

2) Always come to a complete stop before

leaving truck. Be sure travel control is in
NEUTRAL.

250D7EOM42

3) Lower forks fully to floor and tilt forward.

250D7EOM44

4) Set parking brake.

Position 1 : OFF(Release)
Position 2 : ON(Lock)
5) Turn key to OFF position.
1
START
2
ON
OFF

160D7OM37

1-15
14. REFUELING

1) Before adding oil, check around truck for oil

leakage.

250D7EOM47

2) Keep away from fire when adding oil or

during operation.

DIESEL
250D7EOM48

3) After adding oil, wipe off any oil spilled on

truck.

250D7EOM49

1-16
15. STEP

1) When getting on or off the truck, use the

step provided.

250D7EOM50

2) Do not jump up or down from the truck.

250D7EOM52

1-17
 16. OPERATOR'S SAFETY RULES

1) All operational functions require that the

operator be seated in the operator's seat.

Always buckle up if a seat belt is

provided.

250D7EOM18

2) Parking brake must be locked in the PARK

POSITION before exiting from the vehicle.

Parking brake must remain locked in the 1. OFF(DRIVE)

park position(ON) except when an
operator is in the normal operating
2. ON(PARK)
position.

160D7OM24

3) ASME/ISO 3691 REGULATIONS(TRUCK FOR USA OR EQUIPPED WITH A *OPSS)

This forklift truck is equipped with an Operator Existence Sensing System per ASME/ISO
3691.

(1) Traction safety warning

Η This function works when the key switch is ON or START position.
Θ The transmission(power automatically cutoff) in 2 seconds from the driver's off the seat.
Ι At the same time, the warning lamp and alarm will sound intermittently if drive lever was not
returned to neutral.
Κ To release the function, the forward-reverse lever must be cycled through neutral with the
operator in the normal operating position to regain powered directional control.
(2) Parking brake warning
Η This function works when the key switch is not only ON or START position but also OFF position.
Θ Alarm sounds in 2 seconds from the driver's off the seat with the parking lever released.
Ι To release the function, the parking switch must be turned to ON(PARK) position.
Κ When the key switch is OFF position, alarm will sound only for 30 seconds .

*OPSS : Operator Presence Sensing System

1-18
 2. OPERATING HAZARDS
1. LOOSE LOADS

Loose or unbalanced loads are dangerous.

Observe these precautions.
Never carry loose or uneven material.

250D7EOM53

Center wide loads.

250D7EOM55

Stack and band loose material.

D35AOM41

Avoid sudden braking or starting

When the truck is loaded, do not drive at
maximum speed.

250D7EOM56

2-1
2. LONG AND WIDE LOADS

With long or wide loads, you need more

room. So slow down and watch your
clearance.
When extra-long material makes it
necessary to travel with the load elevated,
do so with extreme care and be alert to
load end-swing when turning.
A long load reduces the capacity of the
truck. Know and understand your truck
load rating.
250D7EOM57

3. REAR SWING

When turning, be sure the rear end of

the truck does not swing into racks,
posts, etc. Watch for pedestrians beside
the truck.

250D7EOM43

2-2
4. LOW OVERHEAD CLEARANCE

Know the height of your truck, with and

without a load. Check your clearances.
Keep the load low and tilted back.

250D7EOM73

Watch overhead clearance:

Moving into overhead structures can tip
a truck over, or spill a load.

250D7EOM74

5. FAST TURNS AND HIGH LOADS

Slow down before turning.

The truck can tip over.

250D7EOM46

Turn too sharp with a raised load and

your truck can tip even at slow speeds.
Travel with a load raised only when
removing or depositing a load.

250D7EOM56

2-3
6. RIGHT ANGLE STACKING

When right angle stacking or moving with

a raised load to clear low objects, avoid
sharp turns and move slowly.

250D7EOM75

7. CHAIN SLACK

Slack chains mean rail or carriage hang-

up.
Raise the forks before you move, or
broken chains can result.
In case forks with loads are stuck while
lowering the mast, lift the mast again and
prevent chains from being slack.

D35AOM51

D35AOM52

2-4
8. PALLETS AND SKIDS

Do not move or store materials on

damaged pallets or skids. Items can fall
through them causing severe injury or
death.
Be sure the pallet or skid you are using
is in good condition and does not have
defective or missing components and
fasteners.

D35AOM53

9. CAUTION FOR ELECTRICAL LINES

When moving the truck with the mast

raised, watch out electrical lines over the
truck.
The operating near the electrical lines is
very dangerous.
Operate within safe working permitted as
below.

Supply voltage Min safe separation

250D7EOM76
6.6 kV 3m (10ft)
33.0 kV 4m (13ft)
66.0 kV 5m (16ft)
154.0 kV 8m (26ft)
275.0 kV 10m (33ft)

If the truck touches the electric power

lines, keep sitting on the operator’s seat
and make sure the personnel on the
ground not to touch the truck until turning
off the electric current.
Jump off the truck without contacting the 250D7EOM77
truck when you need to get off.

2-5
10. LIFTING LOADS

Never permit any persons to stand or

pass under lifted load.

250D7EOM58

Never use wire rope to lift a load.

250D7EOM60

2-6
 3. KNOW YOUR TRUCK
1. GENERAL LOCATIONS

1) 250D-7E

11
8

14
1
2 17
3

13

15
4
6 12

10
7
9

16

1 Mast 7 Tilt cylinder 13 Bonnet

2 Lift chain 8 Cabin 14 Counterweight
3 Lift cylinder 9 Head light-fender 15 Rear wheel
4 Fork positioner cylinder 10 Work lamp-mast 16 Front wheel
5 Carriage 11 Work lamp-cabin rear 17 Rear combination lamp
6 Forks 12 Operator's seat

3-1
2. DATA/SAFETY PLATE AND DECAL

1) TRUCK DATA AND CAPACITY PLATE

1 1

75, Yulgok-ro, Jongno-gu, Seoul, 03058, Korea

2 75, Yulgok-ro, Jongno-gu, Seoul, 03058, Korea
2
3 3

4 4

5
5

EXCEPT USA FOR USA ONLY

(1) Truck model number or registered name

(2) The type is represented a kind of truck such as diesel.
(3) Truck serial number
An identification number assigned to this particular truck and should be used when requesting
information or ordering service parts for this truck from your authorized HYUNDAI dealer. The
serial number is also stamped on the frame.
(4) Attachment description(If any installed)
The user must see that the truck is marked to identify the attachment(s), including the weight of
the truck/attachment combination and truck capacity with the attachment.
(5) Capacity rating, load center, and lifting height data
Shows the maximum load capacity of this truck with relation to load centers and fork heights(See
diagram on plate). Personal injury and damage to the truck can occur if these capacities are
exceeded.
Do not exceed the maximum capacity specified.
(6) Truck weight
The approximate weight of the truck without a load on the forks. This weight plus the weight of
the load must be considered when operating on elevators, elevated floors, etc. to be sure they are
safe.
Before modifications that affect the stability of safety systems are made written approval
from HYUNDAI. This is an OSHA requirement. Contact your authorized HYUNDAI dealer
for a new nameplate showing the revised capacity.

3-2
 2) OPERATOR SAFETY WARNING DECAL

Safety and warning decals are placed in conspicuous locations on the truck to remind you
of essential procedures or to prevent you from making an error that could damage the truck or
possibly cause personal injury. You should know, understand, and follow these instructions.
S a fe t y a n d wa r n i n g d e c a l s. S h o u l d b e r e p l a c e d i m m e d i a t e l y i f m i s s i n g o r
defaced(Damaged or illegible). Refer to the page 0-3 for the location of all 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 injury in the event of a truck-tipping or
driving off a dock mishap.
Lift trucks can be tipped over if operated improperly. Experience with lift truck accidents has
shown that the driver cannot react quickly enough to jump clear of the truck and cabin as the
truck tips. To protect operators from severe injury or death in the event of a tip over, it is best to be
held securely in the seat. So, please, always buckle up when driving your lift truck.

3-3
 3. CAB DEVICES

1) The ergonomically designed console box and suspension type seat provide the operator with
comfort.
2) ELECTRONIC MONITOR SYSTEM
(1) The centralized electronic monitor system allows the status and conditions of the truck to be
monitored at a glance.
I t (2) is equipped with a safety warning system for early detection of truck malfunction.

Front

Rear

Radio and USB palyer

Cluster Monitor(opt)
Remote control lever
Multi function switch
Steering wheel Starting switch
Gear selector lever Aircon & heater switch
Inching pedal Handsfree(opt)
Transmission Cigar lighter
error display Switch board

Brake pedal
Accelerator pedal
Operator seat

3-4
 4. CLUSTER
1) STRUCTURE
The gauges panel consists of gauges and monitors as shown below, to warn the operator in case
of abnormal truck operation or conditions for the appropriate operation and inspection.
 Gauges : Indicate operating status of the truck.
 Warning lamp : Indicate abnormality of the truck.
 Pilot lamp : Indicate operating status of the truck.
ö The monitor installed on this truck does not entirely guarantee the condition of the truck.
Daily inspection should be performed according to chapter 7. PLANNED MAINTENANCE
AND LUBRICATION.
ö
When the monitor provides a warning immediately check the problem, and perform the
required action.

Head light pilot lamp Right turning pilot lamp

Left turning pilot lamp Transmission temperature
Brake fail warning lamp warning lamp
T/M error warning lamp Engine coolant temp
warning lamp
Parking brake pilot lamp
Work lamp pilot lamp
Seat belt
warning lamp

OPSS pilot lamp

Engine oil pressure
warning lamp Battery charging
Fuel heater warning lamp
pilot lamp Inching pilot lamp
Water in fuel Air cleaner warning lamp
warning lamp Speed meter LCD Engine coolant temp gauge
Preheater pilot lamp Buzzer stop button Fuel gauge
Engine check lamp T/M oil temperature gauge Fuel low level warning lamp

2) GAUGE
(1) Speed meter
Η The speed meter displays the speed of truck in mph and km/h.

mph

3-5
(2) Fuel gauge
Η This gauge indicates the amount of fuel in the fuel tank.

1/2 Θ Fill the fuel when the indicator moves E point, refuel as soon as
possible to avoid running out of fuel.
E F
ö If the gauge indicates below E point even though the truck is
on the normal condition, check the electric device as that can
be caused by the poor connection of electricity or sensor.

(3) Engine coolant temperature gauge

Η This indicates the temperature of coolant.
H
Red ÂRed range : Above 104ÁC (219ÁF )
Θ Keep idling engine at low speed until the indicator is in the
operating range.
Ι If the indicator is in the red range, turn OFF the engine, check
C
the radiator and engine.

(4) Transmission oil temperature gauge

Η This range indicates the temperature of transmission oil.
H
Red
ÂRed range : Above 107ÁC (225ÁF )
Θ Keep idling engine at low speed until the indicator is in the
operating range.
Ι If the indicator is in the red range, it means the transmission is
C
overheated. Be careful that the indicator does not move into the
red range.

3) WARNING AND PILOT LAMP

(1) Engine check lamp
Η This lamp lights ON during a nonfatal engine system error. The
engine can still be run, but the fault should be corrected as soon
as possible.

3-6
(2) Direction pilot lamp
Η This lamp flashes when the signal indicator lever is moved.

(3) Work lamp pilot lamp (front / rear)

Η This lamp lights ON when cabin work lamp switch is pressed.

(4) Head light pilot lamp

Η This lamp comes ON when the main light switch is operated to
2nd step.

(5) Brake fail warning lamp

Η The lamp lights ON when the oil pressure of service brake drops
below the normal range.
Θ When the lamp is ON, stop the engine and check for its cause.
ö Do not operate until the problems are corrected.

(6) Parking brake pilot lamp

Η When the parking brake is actuated, the lamp lights ON.
Check the lamp is OFF before driving.
ö

3-7
(7) Preheater pilot lamp
Η This lamp lights ON when start switch is turned clockwise to the
ON position. Light will turn off after approximately 15~45
seconds, depending on engine temperature, indicating that
preheating is completed.
Θ When the lamp goes out the operator should start cranking the
engine.
ö Refer to page 5-12.

(8) OPSS pilot lamp (option)

Η This signal lamp lights ON when the operator leaves the seat.
Θ Powered travel movement 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.
Ι The forward/Reverse lever must be cycled through neutral with
the operator in the normal operating position to regain
powered direction control.

(9) Inching pilot lamp

Η When the inching switch is pressed, the lamp lights ON.

(10) Engine oil pressure warning lamp

Η This lamp comes ON for a while after starting the engine
because of the low oil pressure.
Θ If the lamp comes ON during engine operation, shut OFF engine
immediately. Check oil level.

(11) Transmission error warning lamp

Η This lamp lights ON and the T/M message display shows the error
codes when an error occurs in the transmission.
Θ Immediately pull the truck to a convenient stop. Stop the engine.
Investigate the cause.
ö Consult a HYUNDAI dealer to investigate the cause.
ö Do not operate until the cause has been corrected.

3-8
(12) Air cleaner warning lamp
Η This lamp operates by the vacuum caused inside when the filter
of air cleaner is clogged.
Θ Check the filter and clean or replace it when the lamp is ON.

(13) Battery charging warning lamp

Η This lamp is ON after key switch is turned ON.

Θ Check the battery charging circuit when this lamp comes ON

during engine operation.

(14) Fuel low level warning lamp

Η Fill the fuel immediately when the lamp is turned ON.

(15) Water in fuel warning lamp

Η This lamp lights up when the water separators full of water or
malfunctioning.
When this lamp lights up, stop the truck and spill water out of
ö
the separator.

(16) Seat belt warning lamp

Η This lamp lights ON for the first five seconds after starting the
truck.

3-9
(17) Engine coolant temperature warning lamp
Η This lamp is turned ON when the temperature of cooling water is
over the normal temperature(104äC, 219äF).
Θ Check the cooling system when the lamp is ON.

(18) Transmission oil temperature warning lamp

Η This lamp informs the operator that transmission oil is above the
specified temperature.


ÂTransmission oil temperature warning lamp ON : Abnormal
ÂTransmission oil temperature warning lamp OFF : Normal
ö When this lamp lights up during operation, stop the engine
and check the machine.

(19) Fuel heater pilot lamp

Η This lamp is turned ON when the coolant temperature is below
10äC (50äF) or the hydraulic oil temperature 20äC ( 68äF).
Θ The automatic fuel warming is cancelled when the engine
coolant temperature is above 60äC, or the hydraulic oil
temperature is above 45äC since the start switch was ON
position.

3-10
4) CLUSTER BUTTON
Each button has the following function.

Buzzer stop button

MENU button Next button

(1) Buzzer stop button

Η This switch is used to stop the buzzer sound.
Θ Stop the buzzer when the switch is pressed.

(2) Menu and next button

Η This switches are used to choose the model or display the
engine error on the LCD.
Θ Model select mode
 The model is displayed on the LCD when the menu button
and next button are pressed simultaneously for
some longer seconds.
 Please don't change your truck model identity because it is
already pre-set on the truck before delivery.
Ι Engine error display
 The engine error is displayed on the LCD when the
menu button is pressed.
 On pressing the next button , next page is displayed in
case the error was occurred 5 or more.
 On pressing the next button once more, the LCD gets
back to normal display status.

3-11
5) LCD
LCD has the functions to display start mode, standby mode, cruise function, model select and
engine error.

NO Display Name Description

1 Start mode  Display initialization state with HYUNDAI logo and
program version.

2 Standby mode  Displays on the idle state.

 Displays rpm, odometer and hourmeter

3  Odometer is on, is activated.

4  Hourmeter is on, is activated.

5 CRUISE function  When cruise switch is on, displays CRUISE READY

message.
ö Refer to the page 3-25.

6  When cruise function is active, displays CRUISE

ACTIVE message.
ö Refer to the page 3-26.

‫ٻ‬

3-12
NO Display Name Description
7 Model select  On model select mode, displays like this image.
ö Refer to the page 3-11.

Engine error  In case of below 4 engine errors displays like this

display image.
ö Refer to the page 3-11.

 In case of over 4 engine errors displays like this

image.
‫ٻ‬

 To display next page in case of over 4 errors, press .

‫ٻ‬

3-13
5.TRANSMISSION MESSAGE INDICATOR

1) TRANSMISSION ERROR DISPLAY

(1) Function
The display can be used with the gear selector. It indicates speed and driving direction as well as
the activated inching.
When driving in the automatic mode, a bar indicator gives additionally also information about the
selected driving range ; 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, combined
with indication of the error number. Also sporadically occurring errors can be indicated.

f d Left side Right side

h S
T
O
P

b a c Central side g
D507CD33

a, f Automatic range(up and down shiftion)

1 Bars b, c, d, Preselected gear

2 Left side For the moment still without function

On the two alphanumerica 16-segment display, the

Central and electric control unit issues the actual state of gear and
3 driving direction. Besides, a two digit error code will be
Right side
indicated via these two segment
4 Spanner g Electronic control unit recognized an error, is flashing
5 Letters STOP h Immediate stop is required(at the moment not activated)

(2) Abbreviations
OC : Open circuit
SC : Short circuit
OP mode : Operating mode
TCU : Transmission control unit
EEC : Electronic engine controller
PTO : Power take off

3-14
2) DO AEB WORK
(1) Start engine after parking the machine on flat floor and blocking wheels.
(2) Release parking brake.
(3) With stepping on the service brake, operate T/M STALL(3 stage).
(To avoid defect of clutch pack, repeat 10 sec of operation and 10 sec of placing neutral)
(4) When the T/M oil temperature reaches 75~80°C, lock the parking brake and then shift gear to
neutral position to keep the machine at LOW RPM.
(5) Connect the AEB STARTER to T/M controller.
(6) Push AEB STARTER over 3 seconds.
(7) Confirm the status of AEB from the DISPLAY.
· Normal operation shows "ST, KR, KV, K1, K2, K3" orderly for 3~5minutes.
· After the succesful completion, it displays "OK".
· With a new controller, it may display "F6" error code before AEB, it will disappear.
(8) In case of abnormal running, it may display "STOP" with the appropriate error code.
(9) After truobleshooting, start the machine again to repeat above.
※ As the STALL operation has to be done, the SERVICE BRAKE must be locked perfectly to avoid
the fatal accident.
※ AEB mode : It controls the disc internal of the transmission, automatically.

3-15
 3) DISPLAY DURING AEB-MODE

Symbol Meaning Remarks

PL AEB-starter is plugged at the
diagnostic plug
ST AEB-Starter-button is pressed
K1......K3 Calibrating clutch K1...K3, KV or
KV, KR KR resp.
_and Kx Wait for start, initialization of clutch
Kx, x : 1, 2, 3, V, R
≡and Kx Fast fill time determination of clutch Kx
=and Kx Compensating pressure determination
of clutch Kx
OK Calibration for all clutches finished Transmission stays in neutral, you have to restart
the TCU(ignition off/on)j after removing AEB-Starter
STOP AEB canceled(activation stopped) Transmission stays in neutral, you have to restart
the TCU(ignition off/on)
STOP and Kx AEB stopped, clutch Kx can't be Transmission stays in neutral, you have to restart
calibrated the TCU(ignition off/on)
Spanner and Kx Kx couldn't be calibrated, AEB Transmission stays in neutral, you have to restart
finished the TCU(ignition off/on)
△E Engine speed too low
→ 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 Transmission temperature not in Transmission stays in neutral, you have to restart
defined range during calibration the TCU(ignition off/on)
FB Operating mode not NORMAL or Transmission stays in neutral, you have to restart
transmission temperature sensor the TCU(ignition off/on)
defective or storing of Calibrated
values to EEPROM-has failed.
FO Outputspeed_not_zero Transmission stays in neutral, you have to restart
the TCU(ignition off/on)
FN Shift lever not in Neutral position Transmission stays in neutral, you have to restart
the TCU(ignition off/on)
FP Parkbrake_not_applied Transmission stays in neutral, you have to restart
the TCU(ignition off/on)
STOP AEB-Starter was used incorrect or Transmission stays in neutral, you have to restart
is defective. Wrong device or the TCU(ignition off/on)
wrong cable used.

3-16
4) INITIALIZING THE INCHING SENSOR
(1) Start engine after parking the machine on flat floor and blocking wheels.
(2) Release parking brake and keep neutral gear shift.
(3) Adjust the inching sensor linkage so that the regular voltage is supplied to inching sensor when
operating the pedal.
(Regular voltage ; Before pedal operation(1±0.1V),
After pedal operation(3.5±0.1V))
(4) Stop the engine and then just KEY ON.(Release parking brake, keep neutral gear)
(5) Connect the AEB STARTER to the T/M controller.
(6) Push AEB STARTER over 3 seconds.
(7) If display shows "▼IP", Step on the pedal fully.
(8) If display shows "▲IP", release "OK"
(9) After the successful completion, it displays "OK".
(10)In case of abnormal running, it may display "STOP" with the appropriate error code.
(11)After troubleshooting, start the machine again to repeat above.
※ Above works are to be done with the parking brake released, so machine's wheels must be
blocked for safety.

5) DISPLAY DURING INCHPEDAL CALIBRATION

Symbol Meaning Remarks

▼IP Push down the pedal slowly until
endposition is reached and hold this
position
▲IP Release the pedal slowly until endposition
is reached
IP blinkt A problem occurred, release the pedal If the expected endposition could not be
slowly until endposition is reached reached, release the pedal and try again
OK Finished inchpedal calibration successful
FN and Stop Shift lever not in Neutral position Calibrations is aborted
FS and Stop Sensor supply voltage AU1 is out of the Calibrations is aborted
specified range
FO and Stop Output speed is not zero Calibrations is aborted
SL and Stop Sensor voltage below specified range Calibrations is aborted
SU and Stop Sensor voltage below specified range Calibrations is aborted
IL and Stop Sensor position for released pedal out of Calibrations is aborted
specified range
IU and Stop Sensor position for pressed pedal out of Calibrations is aborted
specified range
TO and Stop Time-out calibration, pedal not moved after Calibrations is aborted
calibration start
DL and Stop Angle between pedal positions released Calibrations is aborted
and pressed to small
DU and Stop Angle between pedal positions released Calibrations is aborted
and pressed to big
FI and Stop Sensor signal 1 and 2 don't match together Calibrations is aborted

3-17
 6. SWITCHES

Cruise set-resume switch

Cruise switch
Cover
Parking with lock switch
A Auto/Manual select switch
Inching switch
Cover(LH)
Main light switch
Work lamp switch
Hazard switch
Rear wiper/washer switch
Air conditioner switch
Cabin tilt switch Lock lever Seat heat switch
Inc/Decrement switch
Engine mode switch
Fuel heater switch
p A

Cover
POW
ER

DETAIL A STA
ND
ARD

Cabin tilt switch location

Multi function switch Switch panel

Center horn

Master switch

Start switch

250D7ECD05

1) START SWITCH
(1) There are three positions, OFF, ON and START.
· (OFF) : None of electrical circuits activate.
· (ON) : All the systems of truck operate.
· (START) : Use when starting the engine.
Release key immediately after starting.
77073CD41

3-18
2) HAZARD SWITCH
(1) Use for parking, or loading truck.
OFF
ON ö If the switch is left ON for a long time, the battery may be
discharged.

3) INCHING SWITCH
(1) If this switch is pressed, inching operation is applied to inching
pedal.
(2) Also, inching lamp on the cluster is illuminated.

4) PARKING WITH LOCK SWITCH

RELEASE (1) This switch is used to lock or release parking brake of the truck.
BUTTON (2) If this switch is pressed, the parking brake is applied and the gauge
ON panel warning lamp will comes ON.
ö When operating the gear selector lever, be sure to release the
P

parking brake. If the truck is operated with the parking brake

engaged, the brake will overheat and may cause the brake
system to go out of order.

5) MAIN LIGHT SWITCH

(1) This switch is used to operate the clearance lamp and head light by
two steps.
ÂFirst step : Clearance lamp and cluster illumination lamp
comes
ON. Also, all of the indicator lamps of switches
come ON.

6) WORK LAMP SWITCH

(1) This switch is used to operate the front and rear work lamps by two
steps.
ÂFirst step : Front work lamp comes ON.
ÂSecond step : Rear work lamp comes ON.

3-19
7) REAR WIPER AND WASHER SWITCH
(1) This switch is used to operate the rear wiper and washer by two
steps.
ÂFirst step : The rear wiper operates.
ÂSecond step : The washer liquid is sprayed and the rear wiper is
operated only while pressing. If release the switch, return to the
f i r s t s t e p position.

8) AUTO/MANUAL SELECT SWITCH

1
(1) Manual mode(Η)
2 Press the top of the switch for the manual mode of the autoshift
M

3 function. The operator selects the desired speed and the desired
1

direction in the manual mode with the gear selector lever.

M

2
A

(2) Automatic 1st mode(Θ)

A
A

Place the switch in the middle position for the autoshift function
changing from 1st to 3rd gear shift mode.
(3) Automatic 2nd mode(Ι)
Press the bottom of the switch fully for the autoshift function
changing from 2nd to 3rd gear shift mode.

9) INC/DEC SWITCH
(1) When engine running, the low rpm of engine increase or decrease
OFF
ON by 25rpm by operating this switch.
(2) Engine low rpm returns to normal value when engine restarted.

SEAT HEAT SWITCH

(1) This switch is used to heat the seat.

CABIN TILT SWITCH

(1) Tilting UP cabin
UP Press the top of the switch fully to tilt the cabin upward.
STOP
DOWN
(2) STOP the tilting operation(Default)
Release the switch to stop the tilting operation.
(3) Tilting DOWN cabin
Press the bottom of the switch fully to tilt the cabin downward.
ö Refer to page 7-17 for cabin tilting procedure.

3-20
CENTER HORN
Horn button (1) If you press the button on the top of the multifunction switch and the
center of the steering wheel, the horn will sound.

CAB LAMP SWITCH

(1) This switch turns ON the cab room lamp.

MULTI FUNCTION SWITCH

O J Ɇ
ɇ (1) Front wiper and washer switch
Η When the switch is in J position, the wiper moves intermittently.
Θ When placed in Ɇ or ɇ position, the wiper moves continuously.
Ι If you push the grip of the lever, washer liquid will be sprayed and
the wiper will be activated 2-3 times.
ö Check the quantity of washer liquid in the tank. If the level of
the washer liquid is LOW, add the washer liquid (In cold, winter
days) or water. The capacity of the tank is 1 liter.

(2) Turning switch

Η
This switch is used to warn or signal the turning direction of the
truck to other vehicles or equipment.
Θ
Push the lever up for turning left, pull the lever down for turning
right.

CRUISE SWITCH
OFF
(1) When this switch is turned ON, the CRUISE READY mode is
ON selected and CRUISE ACTIVE is ready for activation.
(2) When this switch is turned off, the CRUISE function is cancelled.
SE L
UI RO
CR NT
CO
ö Please refer to "CRUISE SET/RESUME SWITCH" for the detail
functions.

3-21
CRUISE SET/RESUME SWITCH
(1) Auto cruise function is used to travel at constant engine speed with
RESUME
CRUISE a desired engine rpm.
SET (2) This function is activated only when the CRUISE SWITCH is turned
E
M
U
S

ON. If you want to travel the truck at constant speed, you raise the
E
R

SE
UI T
CR SE

engine rpm and then press the CRUISE SET switch.

(3) By pressing the brake pedal, the truck is shifted to the CRUISE
READY mode.
By pressing the RESUME, the engine rpm gets back to the previous rpm.
ö The cruise function does not work when the INCHING switch is
turned ON.
ö This switch can adjust the engine rpm when the truck is placed in
the CRUISE ACTIVE mode.
ÂRESUME : up by 25 rpm
ÂSET : down by 25 rpm
ö The "CRUISE READY" or "CRUISE ACTIVE" is displayed on the
LCD when the CRUISE function is activated.
Please refer to the page 3-12 for the detail displays.

ENGINE MODE SWITCH

(1) This switch offers two selectable operating mode.
POWER
STANDARD
The operator can adjust the machine's performance with this
selection switch.
R
E

(2) Function
W
O
P

RD

Η STANDARD MODE : This mode provides maximum fuel efficiency

DA
AN
ST

for general loading.

Θ POWER MODE : This mode provides maximum power output
for heavy loading or hill climb.

MASTER SWITCH
(1) This switch is used to shut off the entire electrical system.
F
OF When the machine is not operated for a long time, turn OFF the
master switch for the safety purpose.
(2) I : The battery remains connected to the electrical system.
DIS
C ON
N

O : The battery is disconnected to the electrical system.

ö Never turn the master switch to OFF with the engine running.
Engine and electrical system damage could result.

FUEL HEATER SWITCH

(1) This switch is used for the fuel heater of the pre-heater assy.

3-22
AIR CONDITIONER SWITCH
(1) This switch is used to turns ON or OFF the compressor.
OFF
ON

3-23
7. CONTROL DEVICE

Lift lever
Tilt lever
Steering wheel Fork positioner for LH
Gear selector lever Fork positioner for RH
Inching pedal Option lever

Steering wheel
lever
Brake pedal
Accelerator pedal

1) LIFT LEVER
(1) LIFT
PULL the lever BACK to LIFT the forks.
Lower
(2) LOWER
Lift PUSH the lever FORWARD to LOWER the load.
(3) HOLDING
When the lever is released, the lifting or lowering action stops.
ö Lifting speed is controlled by accelerator pedal.
Lowering speed is controlled by lever only.
2) TILT LEVER
Tilt (1) TILT FORWARD
forward PUSH the lever FORWARD to tilt mast FORWARD.
(2) TILT BACKWARD
Tilt PULL the lever BACK to tilt mast BACKWARD.
backward
(3) HOLDING
When the lever is released, tilting action stops.
ö Forward and backward tilting speeds are controlled by tilt lever
and accelerator pedal.

3-24
3) FORK POSITIONER
Switch 刮 LH FORK MOVEMENT
Outward
- Push the lever forward to move outward for the LH fork.
- Pull the lever backward to move inward for the LH fork.
Inward
## - In case of switch operation, this lever becomes side shift which is
actually performed by both fork movement.

刯 RH FORK MOVEMENT
Outward
- Push the lever forward to move outward for the RH fork.
- Pull the lever backward to move inward for the RH fork.
Inward

4) OPTION LEVER

Switch
OPTIONAL ATTACHMENT MOVEMENT
- Push and pull the lever for optional operation operates.
- In case of switch operation, this lever operates one more

attachment.

5) GEAR SELECTOR LEVER

(1) This lever is used for gear selection, forward 3 stages and reverse 3
stages.
(2) If you push the gear selector lever, the truck moves forward, but
pulling the gear selector lever, the truck moves backward.
(3) If you turn the gear selector lever forward, the truck increases the
speed, but if you turn the gear selector lever backward, the truck
reduces the speed.

3-25
6) STEERING WHEEL
(1) A steering cylinder in the center of the steering axle will operate the
Left Right
steering function.
(2) Turning the steering wheel left, the truck moves to the left side and
turning it right, the truck moves to the right side.

7) BRAKE PEDAL
(1) If the pedal is pushed, braking force is generated and bring the truck
to a stop.
ö Do not operate the truck with stepping on the brake pedal
unnecessarily, or bring premature wear of brake disc.

8) ACCELERATOR PEDAL
(1) This pedal controls the engine speed. The engine speed will
increase in proportion to the degree of force applied to this pedal.
(2) Unless this pedal is pressed, the truck will run at low idling.

9) INCHING PEDAL
(1) Inching pedal is used for fine control of forward and reverse
movement when lifting up or putting down loads.
ö Do not put your foot on the inching pedal or brake pedal unless
using it.

10) STEERING WHEEL LEVER

(1) By pulling down the lever, the wheel is adjustable to tilt.

(2) By pulling up the lever, the wheel is adjustable to

telescope.

3-26
8. AIR CONDITIONER AND HEATER

Air conditioner and heater are equipped for pleasant operation against outside temperature and
defrost on window glass.

Fan speed control switch

Inlet change over switch
Air position control switch
Temperature control switch

Air conditioner switch

3-27
1) FAN SPEED CONTROL SWITCH
3 (1) It is possible to control the fan speed to four steps.
2 4
1

2) AIR POSITION CONTROL SWITCH

3 (1) This switch regulates the air position.
Η Front
2 4 Θ Front & rear
Ι Rear
1 5 Κ Front & defrost
Λ Defrost

3) TEMPERATURE CONTROL SWITCH

(1) This switch regulates the temperature of air.
BLUE RED
- Right side(red zone) : Heat up air temperature
- Left side(blue zone) : Cool down air temperature

4) INLET CHANGE OVER SWITCH

(1) If this switch is pressed, air from the outside is inhaled
(2) If this switch is not pressed, air in the cab is recirculated.

3-28
9. OTHERS

Engine Front
control unit(ECU)
Radio and USB player

Rear

Transmission
control unit(TCU)

Monitor(opt)

Cigar lighter
Handsfree(opt)

Fuse box

Seat

3-29
1) SEAT
The seat is adjustable to fit the contours of the operator's body. It will reduce operator fatigue due
to long work hours and enhance work efficiency.

(1) Forward/Backward adjustment

Pull lever (A) to adjust seat forward or
backward.
C (2) Upward/Downward adjustment
Push or pull the height adjust lever (B) to adjust
seat upward or downward.
F
(3) Reclining adjustment
Pull lever (D) to adjust seat back rest.
(4) Arm rest adjustment
B
D This can be adjusted by turning the handle (F)
E to right and left.
A
(5) Cushion adjustment (E)
Adjusting handle to the operator's weight.
(6) Shoulder rest (C)
The shoulder rest can be adjust to upside.
ö Refer to page 5-8 for the details.

2) CIGAR LIGHTER
(1) This can be used when the engine starting switch is ON.
(2) The lighter can be used when it springs out in a short while after
24V being pressed down.
ö Service socket
Use cigar lighter socket when you need emergency power.
Do not use the lighter exceeding 24V, 100W.

3-30
 3) FUSE BOX

ILLUM.LAMP
START KEY
(1) The fuses protect the electrical parts and wiring
10A
from burning out.

SPARE(15A)
ࢠ
݊
FUSE
HOLDER
FUSE
F/WARMER(PRE)
TCU(B+) (2) The fuse box cover indicates the capacity of each
઴߹ુવ 10A
15A
ඹࠤෂഉ
fuse and circuit it protects.
TURN LAMP HORN(B+)
ECU
FRONT 10A
15A 5A
10A ΢ ö Replace a fuse with another of the same
ୢࢺୁડ݊ ଲ੨କ
SPARE(10A)

OPSS(B+) NEUTRAL
MONITOR(B+)
capacity.
REAR 15A
5A RELAY 5A
Before replacing a fuse, be sure to turn OFF the
บࢺୁડ݊ ஂ෍ࠧߑଲ
WIPER MOTOR/
ECU(B+) TCU
CABIN TILT
starting switch.
HORN 15A 15A
૕ଲ൵ࡦഉ෻ ൖ੨କ

HEAD LAMP
ECU(B+) BRAKE LAMP
CLUSTER(B+)
SPARE(5A)

15A 5A
෤݁޽ඹ जߑଲ೥޽ඹ

BEACON LAMP
CD/MP3(B+) CLUSTER
ROOM LAMP
5A 5A
լֈ݊ ծ‫׆‬ൡ

ENGPREHEAT
E/G PREHEAT ILLUM.LAMP
START KEY
10A  10A

SPARE(15A)
SPARE(15A)

ફ஼ુવ ਏ‫ܛ‬೬
FUSE FUSE
FUSE
HOLDER FUSE
HOLDER
BACK-UP TCU(B
FUEL +)
WARMER
5A  15A
ࢽડ޽ඹऀୠ ൖ੨କ
FRONT
OPSS PARKING
PARKING TURN LAMP ECU +)
HORN(B
10A 10A   WORK LAMP 15A
10A 10A
5A 
૶ୢୀԮ஺ୋ౿ சఙ ࢺේ஺ਏ݊ լଣ‫׆‬
SPARE(10A)
SPARE(10A)

CIGAR JACK/ NEUTRAL+)

CIGAR-JACK SEAT HEATER OPSS(B+)
REAR
WORK LAMP 5A
MONITOR(B
RELAY
 15A
TILT ALARM 10A 15A   ૶ୢୀԮ஺ୋ౿ 15A 5A 
ਏԧ୎൙ൈੵ‫ޱ‬ ਏൈ
વট ࡦ‫ۍ‬ഉ
DC AIRCON/ WIPER MOTOR/
DC
CONVERTER AIRCON
HEATER
ECU(B+)
HORN
CABIN
TCU TILT
 15A 15A
20A   15A 15A 
%$
ಟ࣊ഉ ઩ઘ಺ํഉ ଲ੨କ ಑थ
൙൝

ECU(B +) CLUSTER(B
LAMP)
+
FDCU
TILTFDCU
ALARM MONITOR HEAD LAMP BRAKE
SPARE(5A)
SPARE(5A)

 ൬
ুܑ
୪ઘ‫׆‬
5A 5A   15A 5A 
ࡦ‫ۍ‬ഉ ଲ੨କ ծ‫׆‬ൡ

CD/MP3 F/WARMER
HANDS FREE CDMP3(B
BEACON +)
LAMP ROOM
CLUSTER
 15A
$%
රߑଲઘ 10A (MAIN) 15A
10A   5A 5A 
ිலඹࠤ ઴߹ુવࡔ
଴ෂഉ
$%
රߑଲઘ ਓٛ݊

4) TRANSMISSION CONTROL UNIT(TCU)

(1) The control unit is shifting the required speeds fully-automatically
under consideration of the following criteria.
 Gear selector lever position
 Driving speed
 Load level

3-31
8) MONITOR(OPTION)
ÂAdjusting the angle
Upwards and downwards up to 7ä total 14ä. Swivels left and right up to 15ä total 30ä.

Up

Down
LCD
Left
Right

Power button Enter button

Left selection button Right selection button

Camera / ESC button

(1) Power button

Η To turn the power off or on.
Θ To switch the monitor on or off, press and hold the power button for
two second.

(2) Left / right selection button

Η Select button allow you to select various monitor options and to
input passwords.

(3) Camera / ESC button

Η To enter camera screen, press the Camera/ESC button at the menu
selection screen.
Θ To return to the menu selection screen, press the Camera/ESC
button on the camera screen.
Ι To cancel menu selection or escape from the menu, press the
Camera/ESC button.

(4) Enter button

Η To choose the option, press the enter button.

3-51
(5) LCD
No Name Description
1 ESL(Engine Starting Limit) screen The password must be 5~10
digits long. After input password,
you must input .
öDefault password :
'0000000000'(digit '0', 10
times)

2 Menu selection screen

3 Camera selection To enter camera screen, press

the or button.
To return to menu selection
screen, press button.‫ٻ‬

4 ESL mode selection  Disable :

 ESL : Engine Starting Limit Not used ESL function.
 ESL mode is designed to be a theft deterrent or will prevent the  Enable(always) :
unauthorized operation of the machine. The password is required
 If the ESL mode was selected Enable, the password will be whenever the operator start
required when the start switch is turned ON. engine.

3-52
No Name Description
5 Changing password The password must be 5~10
digits long. After input password,
you must input .

6 Display set up screen  LCD brightness

To adjust to display brightness,
press or to decrease or
increase.

 Language selection

3-53
 4. OPERATOR MAINTENANCE AND CARE
1. DAILY SAFETY INSPECTION

Before using a lift truck, it is the operator's responsibility to check its condition and be sure it is safe to
operate.
Check for damage and maintenance problems; have repairs made before you operate the truck.
Unusual noises or problems must be reported immediately to your supervisor or other designated
authority.
Do not make repairs yourself unless you are trained in lift truck repair procedures and authorized by
your employer. Have a qualified mechanic make repairs using genuine HYUNDAI or HYUNDAI-
approved parts.
Do not operate a truck if it is in need of repair. If it is in an unsafe condition, remove the key
and report the condition to the proper authority. If the truck becomes unsafe in any way while
you are operating it, stop operating the truck, report the problem immediately, and have it
corrected.
Lift trucks should be inspected every eight hours, or at the start of each shift. In general, the daily
inspection should include the visual and functional checks described on the followings.
Leaking hydraulic oil may be hot or under pressure. When inspecting a lift truck, wear safety
glasses and do not check for leaks with bare hands.

1) VISUAL CHECKS
First, perform a visual inspection of the truck and its major components;
(1) Walk around your lift truck and take note of obvious damage that may have been caused by
operation during the last shift.
(2) Check that all capacity, safety, and warning plates or decals are attached and legible.
(3) Check before and after starting engine for leaking fuel, engine coolant, transmission fluid, etc.
(4) Check for hydraulic oil leaks and loose fittings.
Do not use bare hands to check. Oil may be hot or under pressure.
(5) Be sure that the driver's cabin load back rest and all other safety devices are in place, securely
fastened and undamaged. Inspect for damaged or missing parts, corrosion, cracks, breaks etc.
(6) Check all of the critical components that handle or carry the load.
(7) Look the mast and lift chains over. Check for obvious wear and maintenance problems such as
damaged or missing parts, leaks, slack or broken chains, rust, corrosion, bent parts, cracks, etc.
(8) Carefully inspect the load forks for cracks, breaks, bending, twists, and wear. Be sure that the
forks are correctly installed and locked in their proper position.
(9) Inspect the wheels and tires for safe mounting, wear condition, and air pressure.
(10) Check the hydraulic sump oil level, engine oil level, and fuel level.

4-1
2) FUNCTIONAL CHECKS
Check the operation of the truck as follows.
ö Before performing these checks, familiarize yourself with the starting, operating, and
shutdown procedures in Section 5 of this manual. Also, know the safety rules given in
Section 1 of this manual.
(1) Test warning devices, horn, light, and other safety equipment and accessories.
(2) Start the engine and be sure all controls and systems operate freely and return to neutral properly.
Check the:
Η Gauges, meters, and indicator lights
Θ Service brakes, inching pedal, and parking brakes
Ι Hydraulic controls: lift, tilt, and auxiliary(If installed)
Κ Accelerator
Λ Directional control
Μ Steering system
Ν Lift mechanism and any attachments.
When the functional check are completed, follow the standard shutdown procedures given in
Section 5, Starting and operating procedures.
3) CONCLUDING THE INSPECTION
Do not operate a lift truck that has a maintenance problem or is not safe to operate.
(1) Instead, remove the key from the starting switch and put an
Out of service tag on the truck.
(2) If all of the daily inspection checks were normal or satisfactory,
the truck can be operated.

D35AOM1050

4-2
2. SUGGESTION FOR NEW TRUCK

1) It takes about 100 operation hours to enhance its

designed performance.
2) Operate according to below three steps and avoid
excessive operation for the initial 100 hours.

Service meter Load Avoid excessive

operation for
initial 100 hours
Until 10 hours About 60%
Until 100 hours About 80%
After 100 hours 100%
ö Excessive operation may deteriorate the
potential performance of truck and shorten
lifetime of the truck.

3) Be careful during the initial 100 hours operation.

(1) Check daily for the level and leakage of coolant,
250D7EOP01
engine oil, hydraulic oil and fuel.
(2) Check regularly the lubrication and fill. Grease
daily all lubrication points.
(3) Tighten bolts.
(4) Warm up the truck fully before operation.
(5) Check the gauges during operation.
(6) Check if the truck is operating normally during
operation.
4) Replace following after initial operation hours.

Checking items

Engine oil
50
Engine oil filter element
Axle gear oil
Transmission oil
100
Transmission oil filter
Brake cooling oil

4-3
3. FUEL SAFETY PRACTICES

REFUELING DIESEL TRUCKS

100D7OM106

Stop the engine when refueling.

All lights and flames shall be kept at a
safe distance while refueling.

D35AOM106

DANGER
DIESEL
FLAMMABLE

USE CLEAN, PROPERLY MARKED FUEL CANS

D35AOM106

CLEAN UP SPILLS

D35AOM106

4-4
 5. STARTING AND OPERATING PROCEDURES
1. BEFORE OPERATING THE TRUCK

Be sure that you have read and understand the information in this Operator's Manual and are trained
and authorized before operating the lift truck.
A lift truck can be dangerous if not used properly. Safe operation is the responsibility of the
operator.
Do not start or operate the truck, or any of its functions or attachments, from any place other
than the designated operator's position.
Inspect your lift truck before operating at the start of each shift. Before putting your truck to
use, check the operation of the controls and all systems.
Protect yourself. Do not operate truck without closing the cabin door or without fastening seat
belt unless conditions prevent its use.
Use special care if operation without these safety rules are required.

5-1
2. CHECK BEFORE OPERATION

1) The Occupational Safety and Health Act(OSHA) required that truck users examine their trucks
before each shifts to be sure they are in safe working order. Defects when found shall be
immediately reported and corrected. The truck shall be taken out of service until it has been
restored to safe operating condition.

12
1
11

2
1 Oil leakage
2 Tire air pressure
10 3 Coolant level
4 Engine oil level
9 5 Fan belt tension
7 6 Battery
7 Brake cooler oil level
6
8 Hydraulic oil level
8
9 Water separator
3 10 Multi function switch
11 Pedals
4 5 12 Axle oil level

250D7EOM51

2) A thorough walk-around check should be made BEFORE starting engine. This is required for your
personal safety and to realize maximum service life for your truck.
Η The numbers on the inspection chart show the order of inspection
Θ These numbers correspond to the check item numbers given on the next pages.
Ι Hang a caution sign on the truck(for example, Do not start or Maintenance in progress).
This will prevent anyone from starting or moving the truck by mistake.

5-2
3. CHECK BEFORE STARTING ENGINE

1) CHECK FOR WATER OR OIL LEAKAGE

(1) Walk around your HYUNDAI truck and check for water, oil or hydraulic leakage. Examine truck for
obvious damage.
(2) Check cabin, backrest and forks for crack or obvious damage.
(3) If any damage or leaks are detected contact your HYUNDAI dealer or tire repair shop.
2) CHECK TIRE AIR PRESSURE/CHECK TIRE RIM
• Air pressure and torque
Item Unit Front tire Rear tire
kgf/cm 2
10.9 10.9
Tire air
psi 156 156
pressure
bar 10.6 10.6

Hub nut kgfÂm 35Ü2 83.5Ü12.5

tightening lbfÂft 253Ü14 604Ü90
torque
N.m 343Ü19 818Ü122

The tires are under high inflation pressure, so failure to follow the correct procedures when
changing or servicing tires and rims could cause the tire to explode, causing serious injury or
damage. The tires and rims should always be serviced or changed by trained personnel
using the correct tools and procedures. For details of procedures, contact your HYUNDAI
dealer or tire repair shop.
If there is any deformation, damage, or wear of the rim, or any doubt about the condition,
always replace the rim. Never try repairing, welding, or heating.

5-3
3) CHECK COOLANT LEVEL
(1) If the cooling water in the radiator sub-tank is not within normal
Max range when cool, add water to the MAX line.
Normal HY
UN
DA
I

Min
FU
LOLL
W

160D7OM61

In antifreeze is being used, pay careful attention to the ratio of antifreeze and water when
adding coolant.
If the sub-tank is completely empty, first add water directly to the radiator. Then add water to
the sub-tank.
Always allow the radiator to cool down before adding water.
At the operating temperature, the engine cooling water is at high temperature and pressure,
so it is dangerous to try to open the radiator cap. Wait until the radiator is cool enough to be
touched by hand before opening the radiator cap. Loosen the radiator cap slowly to release
the pressure, then loosen the cap.

4) CHECK OIL LEVEL IN ENGINE OIL PAN

(1) Stop the engine, pull out the dipstick and check the oil level.

H (2) The oil surface line on the dipstick should be between H and L.
NORMAL If below L, remove the filler cap and add engine oil through the
L oil level.

D35AOM112

ö Change the oil if it is marked dirty or discolored.

Oil level is to be checked with the truck placed at flat level and at least 3 minutes after the
engine stopped.
Do not touch hot components or allow hot oil to contact your skin.

5-4
5) CHECK FAN BELT TENSION
Cooling fan belt tensioner
Maintenance check
(1) With the engine turned off, check that neither the top nor
bottom tensioner arm stop is touching the cast boss on the
tensioner body. If either of the stops is touching a boss, the
7807AMI50
alternator belt must be replaced. Check to make certain the
correct belt part number is being used if either condition exists.
When using a steam cleaner, wear safety glasses or a face
shield, as well as protective clothing. Hot steam can cause
serious personal injury.
Wear safety glasses or a face shield, as well as protective
clothing, to prevent personal injury when using a steam
cleaner or high-pressure water.
Check the tensioner pulley and body for cracks. If any cracks
are noticed, the tensioner must be replaced. Refer to a
cummins authorized repair facility.
Check the tensioner for dirt buildup. If this condition exists, the
tensioner must be removed and steam-cleaned.
With the cooling fan belt removed, check that the bottom
tensioner arm stop is in contact with the bottom tensioner arm
stop boss on the tensioner body. If these two are not touching,
the tensioner must be replaced.

6) CHECK BATTERY
Battery maintenance need serious care and safety service.
Refer to 10. REPLACEMENT AND CHECK in SECTION 7.
and always keep the safety rules.

160D7EOM36

7) CHECK BRAKE COOLER OIL LEVEL

(1) Rest fork on ground and stop engine. Pull out dipstick and
check oil level. If insufficient, add oil.
H Hot oil and components can cause personal injury. Do not
NORMAL allow hot oil or components to contact skin.
L

D35AOM112

5-5
8) CHECK HYDRAULIC OIL LEVEL
(1) Rest fork on ground and stop engine.

Upper (2) Check the oil level from the level gauge of hydraulic oil tank.
limit
(3) In accordance with the mast equipped, the oil level differs.
Lower
limit
Gauge ˶(U.S.gal) Mast spec.

Level gauge Lower limit 268 (71) Simplex

160D7MA14 Upper limit 285 (75) Triplex

9) CHECK WATER SEPARATOR

(1) WIF(Water in fuel) warning lamp.
If the warning lamp stays on, drain the water from the fuel filter.

160D7CD15

(2) When the float of separator meets the red line(drain level),
drain water.

Float Drain
level

D35AOM1181

10) MULTI FUNCTION SWITCH

O J Ɇ ɇ (1) Front wiper and washer switch
Η When the switch is in J position, the wiper moves intermittently.
Θ When placed in Ɇ or ɇ position, the wiper moves continuously.
Ι If you push the grip of the lever, washer liquid will be sprayed and
the wiper will be activated 2-3 times.
73033CD29
ö Check the quantity of washer liquid in the tank. If the level of
the washer liquid is LOW, add the washer liquid (In cold, winter
days) or water. The capacity of the tank is 1 liter.

Left turning (2) Turning switch

Η This switch is used to warn or signal the turning direction of the
truck to other vehicles or equipment.
Θ Push the lever up for turning left, pull the lever down for turning
Right turning right.
73033CD31

5-6
11) CHECK PEDALS Interlock stroke with brake pedal
Check for any catching or abnormal Free play
heaviness when depressing the pedals.
(1) Inching pedal
Η Free play : Max 1ä
Θ Interlock stroke with brake pedal : 7ä
(2) Brake pedal
Η Free play : Max 1ä

250D7ETA02

5-7
4. SEAT ADJUSTMENT

1) SEAT ADJUSTMENT
The seat is adjustable to fit the contours of the operator's body. It will reduce operator fatigue due
to long work hours and enhance work efficiency.
(1) Forward/Backward adjustment
(slide adjustment)
Η Pull lever (A) to adjust seat forward or
backward.
C
Θ The seat can be moved forward and backw-
ard over 180mm (7in) in 9 steps.
F (2) Upward/Downward adjustment
(Lift adjustment)
Η Push or pull the height adjuster lever (B) to
adjust seat upward or downward.
B
D Θ Forward or backward side adjustment only
E
can be made, tilting to one side, by pushing or
A
pulling the lever (B) respectively.
The seat can be adjusted 60 mm (4 steps) to
upward at the frontside and rearside
180D7ECD50
respectively.
(3) Reclining adjustment
Pull lever (D) to adjust seat back rest.
The recliner can be slanted until 12 degrees (2
degreesÝ6 steps) to front side and 56 degrees
(2 degreesÝ28 steps) to backside.
(4) Arm rest adjustment
This can be adjusted by turning the handle (F) to
right and left.
The armrest can be adjusted until 55 degrees to
upward and 15 degrees to downward without
steps.
(5) Cushion adjustment (E)
Adjusting handle to the operator's weight.
(6) Shoulder rest (C)
The shoulder rest can be adjust until 170mm
(20mmÝ8 steps+10mm) to upward.

2) BUCKLING UP
(1) Buckling up. Be sure that you put on the seat belt. Connect
and adjust the seat belt strap to a snug, comfortable position.
Always wear your seat belt when operating a lift truck.
Failure to wear seat belt will result in injury or death in an
event of an accident.
160D7OM11

5-8
5. STARTING FROM A SAFE CONDITION

Always start from a safe condition.

Before operating a lift truck, make sure that : ON
 You are safely seated in the truck.

P
 Seat belt is buckled up.
 The parking brake is applied. Parking switch ON
 The forks are fully lowered to the floor or
ground.
 You are familiar with how all the controls
function.
 All controls are in neutral or other correct
position.
 The truck has received its daily inspection 250D7EOM31

and ready and safe to operate.

Put the direction control lever in the NEUTRAL

position, before starting. The truck should start
only in the NEUTRAL position. If it starts in
gear, have the truck serviced. Forward

Neutral

Reverse

160D7OM45

5-9
6. GENERAL STARTING AND OPERATING TIPS

Before you start the truck, make sure that you have taken all the above-mentioned precautions, you
have read this manual, you are starting from a safe condition, with the directional control in NEUTRAL,
the seat adjusted, and your seat belt buckled.
INSPECT YOUR LIFT TRUCK BEFORE OPERATING at the start of each shift. Before you
put your truck to use, check the operation of the controls and all systems.
Turn off any lights or optional electrical equipment while you crank the engine. This reduces the
electrical load on your battery.
Avoid excessive starter cranking(In excess of 30 seconds). To avoid starter overheating or damage,
do not crank the starter continuously for more than 30 seconds at a time. If the engine fails to start,
wait two to three minutes before again attempting to start your lift truck.
If your battery is run down(discharged) or becomes discharged while you try to start your truck, please
refer to Section 6, Emergency Starting and Towing, in this manual.
To avoid damage to your truck or possible harm to yourself. Follow these recommendations :
 Warm the engine up before driving or applying a load. Idle engine at low idle rpm for a few minutes
to circulate and warm the oil. Then increase speed to approximately half-throttle for a short period
or until the engine coolant reaches approximately 100ÁF. This procedure helps prolong engine life.
 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 and make a visual inspection for oil, water, or fuel leaks.
 Do not operate the engine at speeds above idle for more than brief periods without a load.
 Do not run the engine at maximum power continuously until the engine is fully warmed up.
 Never operate the engine at more than the regular no-load governed speed. Excessive speeds are
harmful.
ö The governor is set at the factory and should need no adjustment.
 Avoid extended(in excess of 10 minutes) and unnecessary idling of the engine. Turn off the
engine instead.
 Carbon monoxide is colorless and odorless, but can be present with all other exhaust fumes.
Exhaust gases are harmful and can cause serious injury or death. Proper ventilation is
always necessary for safe inside operation or warm-up.
Due to the precise, tolerances of diesel injection systems, it is extremely important that the
diesel fuel be kept clean and free of dirt or water. Dirt or water in the system can cause
severe damage to both the injection pump and the injection nozzles.

5-10
7. STARTING AND STOPPING THE ENGINE

1) CHECK INDICATOR LIGHTS

(1) Check if parking brake switch is ON.
Gear selector lever
(2) Check if gear selector lever is in neutral position. Parking brake switch
(3) Turn the key to the ON position, and check
following.
Η If all the lamps light ON after sounding buzzer
for 3 seconds.
ö If the lamps do not light or the buzzer is not
sounded, check disconnection of wire.
Θ Only below lamps will light ON and all the other
light will be turned OFF after 3 seconds.
- Charging warning lamp(1)
- Engine oil pressure warning lamp(2)
- Brake fail warning lamp(3)
2 3 1
ö Start the engine after all of the lamps OFF.
(Only above 3 lamps remain ON)

250D7EOP03

2) STARTING ENGINE IN NORMAL TEMPER-

ATURE
ö Sound the horn to warn the surroundings after
checking if personnel or obstacles are in the
area.
(1) Turn the starting switch to START position to
start the engine. START
ö If the engine does not start, allow the starter
to cool for about 2 minutes before attempting ON OFF
to start the engine again.
(2) Release the starting switch instantly after the
engine starts to avoid possible damage to the
starting motor.
(3) The starting switch will automatically return to the
ON position. 77074OP04

5-11
3) STARTING ENGINE IN A COLD WEATHER
ö Sound horn to warn surroundings after
checking if there are obstacles in the area.
ö Replace the engine oil and fuel referring to
recommended oils at page 7-66.
Fill the anti-freeze solution to the coolant as
OFF
required.
(1) Check if the parking brake is locked(With the
parking switch ON).
(2) Check if the gear selector lever is in the neutral
position.
ON
(3) Starting the engine while the ambient tempera-
ture is below 0ÁC.
Η Turn the start key switch to "ON" position.
Θ Wait until the gauge of the monitor should be
set.
Ι Push down the heating symbol ( ) on the fuel START
heater switch so that it can heat the fuel oil
after the heating signal ( ) on the cluster ON OFF
goes out and then wait for 5 minutes. 180D7EOP05
Κ Turn the start key switch to "Start" position.
Λ Release the start key switch when the engine is started.
Μ Keep sufficiently idling condition after starting the engine.
Travelling the machine or operation of the attachments could be caused shut-down of the engine.
ö In the event of the winter season, the fuel oil happens WAX from -6Á
ÁC.
When the ambient temperature is below -6ÁC, do not operate the machine under high load
condition so that it can operate normally the fuel system of the engine, and operate the
machine after keeping idle condition of the engine in a way.
(4) Starting the engine at freeze-up (severe cold winter season) condition.
Η When the ambient temperature is below 0ÁC, carry out the same method according to above
procedure.
Θ Operate the engine in a way so that it can supply a sufficient oil to the engine and hydraulic
system due to heating the oil under low speed and low load condition after starting the engine.
Ι At the severe cold condition below -15ÁC, do not operate the machine under the high load
condition after starting the engine in a way.
Keep the idle condition of the engine for 20~30 minutes at the severe cold condition (freeze-up
condition).

5-12
4) INSPECTION AFTER ENGINE START
Inspect and confirm the following after engine
starts.
(1) Is the level gauge of hydraulic oil tank in the
normal level?
(2) Are there leakages of oil or water?
(3) Are all the warning lamps OFF?
(4) Check the following after warming up operation.
Η Is the indicator of engine coolant temperature
gauge (1) in the operating range?
Θ Is the indicator of transmission oil temperature 2 1
gauge(2) in the operating range?
Ι Is the engine sound and the color of exhaust
160D7EOP06
gas normal?
Κ Are the sound and vibration normal?
ö Do not increase engine speed quickly after starting, it can make damage engine or
turbocharger.
ö
If there are problems in the control panel, stop the engine immediately and correct problem
as required.

5-13
 (5) Check engine exhaust color.
Exhaust gas color Criteria
Colorless, light blue OK
Black Check for incomplete combustion
White Check for oil leakage

(6) Check fuel tank level.

If the indicator points to F, the tank is full. If the indicator
1/2 enters the E range, refill the fuel tank immediately. Do not
operate the truck below this level. Do not use low quality fuel
E F
or fuel mixed with kerosene. Clean the area around the cap
before adding fuel to prevent dirt from entering the tank.
160D7ECD04 Always fill the tank at the end of the day's operation. If air
remains in the tank, the moisture in the air will condense inside
the tank and form water in the fuel.
Do not smoke or allow any flame near the truck when refueling. Refueling produces explosive
fumes. The truck should be refueled only at the specified refueling point.
Stop the engine and get off the truck when refueling.

(7) Check warning lamps.

BRAKE FAIL ENGINE OIL T/M ERROR AIR CLEANER WATER BATTERY FUEL LEVEL SEAT BELT
WARNING LAMP PRESSURE WARNING LAMP WARNING LAMP IN FUEL CHARGE WARNING LAMP WARNING LAMP
WARNING LAMP WARNING LAMP WARNING LAMP
160D7EOM126

ö These lamps light up to indicate an abnormality.

So, if one of these lamps is lighted, take appropriate service and maintenance.

(8) Check steering wheel play.

30-60mm
If the steering wheel play is over 30~60mm (1.2-2.4in), check or
(1.2-2.4 in) repair it.

D35AOM127

(9) Check lift chain tension.

Raise forks 10 to 15cm(4 to 6in) from ground. Push with a rod
to check that both chains have approximately same amount of
slack.
ÂAdjusting lift chain
Η Loosen locknut and turn the adjust nut.
Θ Equalize tension on the lift chain.
Do not put hands into the mast.
160D7OM35

5-14
(10) Check steering wheel.
Check that steering wheel does not wobble or suddenly pull to one side. Check also for any
abnormal heaviness in steering.
(11) Check rear view mirror.
Adjust the rearview mirror for best rearward visibility.

5) TRANSMISSION COLD STARTING

(1) At an oil temperature in the shifting circuit < -12ÁC,
the transmission must be warmed-up for some
minutes.
(2) This must be carried out in neutral with an
increased engine speed. S
T
(3) Until this oil temperature is reached, the electronics
O
remains in neutral, and the symbol of the cold start P
phase will be indicated on the display.
ÂIndication on the display : ∗ ∗
(4) After the indication on the display is extinguished,
the full driving program can be utilized out of
NEUTRAL. 160D7ECD17

6) TO STOP THE ENGINE

ö If the engine is abruptly stopped before it
has cooled down, engine life may be greatly
shortened. Consequently, do not abruptly
stop the engine apart from an emergency.
ö In particularly if the engine has overheated,
do not abruptly stop it but run it at medium
Low idling for
speed to allow it to cool gradually, then stop 5 minutes
it.
(1) Place the gear selector lever in neutral.
(2) Turn the parking brake switch ON.
(3) Run the engine for five minutes at low idle with
no load.
(4) Return the key of starting switch to the OFF
position.
(5) Remove the key to prevent other people using
the trucK.
(6) Lock the cab door. 250D7EOP07

5-15
8. WARMING-UP OPERATION

ö The most suitable temperature for the hydraulic

Á
oil is about 50ÁC (112Á F ).
It can cause serious trouble in the hydraulic Gear selector lever
system by sudden operation when the Parking brake switch
Á
hydraulic oil temperature is below 25ÁC (77Á
F ).
The temperature must be raised to at least
25ÁÁ C (77Á
F ) before starting work.
1) Run the engine at low idling for 5 minutes.
2) Speed up the idling and run the engine at mid-
range speed.
3) Lift the forks slightly and tilt the mast forward to the
stroke end to relieve hydraulic pressure.
ö Do not leave hydraulic pressure relieved for
more than 30 seconds.
4) Tilt back to the stroke end to relieve hydraulic 5 minute
warming-up
pressure.
ö Do not leave hydraulic pressure relieved for
more than 30 seconds.
5) Repeat the procedure 3) - 4) several times until
warm-up operation is completed.

250D7EOP08

5-16
9. LEVERS AND PEDALS

1) POSITIONING FORKS AND MAST

When driving, with or without a load, it is a good practice to always raise the forks slightly and tilt the
mast (forks) backward. Raising the forks and tilting them back prevents the fork tips from catching
on possible obstructions and reduce the wear on the fork blades from striking or dragging on the
floor or ground. See safety messages on next page.

Pull back on the lift control lever and raise

the forks 150 to 200mm(6 to 8 inch) above
the floor. Then, using the tilt control, tilt the Lift

mast back slightly to raise the fork tips. Lower

250D7EOM19

The mount of forward and backward tilt to be

used is governed by the application. Tilt
backward

Tilt
forward

250D7EOM20

When the mast(carriage and/or load) is raised into a high (Elevated) position, the stability of
the truck is reduced.
Some of the other conditions that may affect stability are ground and floor conditions, grade,
speed, loading, dynamic and static forces, and the judgement exercised by the operator.
Trucks equipped with attachments behave as partially loaded trucks even when operated
without a load on the attachment. Also, improper operation, faulty maintenance, or poor
housekeeping may contribute to a condition of instability.
For stability, do not travel with the load or carriage in a highly elevated position. Travel with
the lift mechanism raised only enough to clear the ground or obstacles.

5-17
2) SELECTING DIRECTION OF TRAVEL
Push the direction control lever forward, center it , or pull it back
Forward
for FORWARD, NEUTRAL, or REVERSE, respectively.
Traction is disabled in NEUTRAL.
During traveling in forward or reverse direction, a sudden
Reverse
change of direction can cause to drop a load and damage
160D7OM95 to the machine.

3) USING THE ACCELERATOR PEDAL

With the parking brake released and the direction control in
FORWARD or REVERSE, put your foot on the accelerator
pedal and push down smoothly until the truck is moving at the
desired speed.

160D7OM131

4) BRAKING PEDAL
To stop the truck, lift your foot from the accelerator pedal and
put it on the brake pedal. Push down on the brake pedal in a
smooth, firm motion until the truck is stopped.
Stop the lift truck as gradually as practical. Hard braking
and wheel sliding are dangerous, increase wear, and can
160D7OM132
cause you to loose a load and damage to the lift truck.
Can cause tip-over.

5) INCHING PEDAL
Use the inching pedal and the accelerator pedal in combination
to vary lift and travel speeds independently. The further 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
160D7OM133 your left foot for precise control of travel speed, while you
operate the accelerator pedal together with the lift control to
vary lift speed.
In case of slipping the clutch, it can be caused to happen
heating problem in the system due to excessive friction of
the discs, and reduced a durability or a lifetime of the
components as result.
Pay particularly careful attention to do not press
repeatedly the pedal and it is essential to cut off the
power for travelling by pressing the pedal sufficiently to
prevent from heating problem.

5-18
10. TRAVELING OF THE TRUCK

1) BASIC OPERATION
Tilt back fully
(1) Traveling posture

15-20 cm(6-8in)
Lift the forks so that the forks are placed 15-
20cm(6~8in) above the ground and tilt back the
mast fully.

250D7EOP10

(2) Traveling operation

When warm-up operation is completed after the Gear selector lever
engine is started, move the truck according to Parking brake switch
the following procedure.
Η Release the parking brake.
Θ Put the gear selector lever in the 1st stage of
forward or backward direction and press gently
the accelerator pedal to move the truck.

250D7EOP14

(3) Changing direction and speed

Η The gear selector is designed for the mounting
Forward
on the left side of the steering column.
Θ The positions(speeds) 1 to 3 are selected by a Acceleration
rotary motion, the driving direction Forward(F)- 1
2
F

N
3

Neutral(N)-Reverse(R) by tilting the gear 4

R

selector lever. Deceleration

Ι A neutral lock is installed as protection against Reverse
inadvertent drive off.
ÂPosition N - Gear selector lever blocked in
this position
ÂPPosition D - Driving
N D
Κ When doing work, run the truck in the 1st or 2nd
speed. 77074OP33

5-19
 ※ When traveling at high speed, do not
abruptly decelerate by using the trans-
mission lever, to slow down instead press
the brake pedal.
※ When changing direction, check beforehand
there is no obstacle in the direction you will
be headed.
※ Avoid changing direction at high speed.

(4) Turning the truck

① Turn the truck by moving the steering wheel
into the desired direction. 52
② You can turn the truck to the left or right by
52 degree.
※ Do not turn the truck abruptly when traveling
at high speed and avoid turn on a slope.
Steering does not function with engine OFF.

250D7EOP11

(5) Precautions when driving

① If the monitor warning lamp lights up, put the
gear selector lever in the neutral position and
stop the truck. Stop the engine after running it
at low idling. Then resolve any problems
regarding operation of the truck.
② When operating the truck, if the load is lighten
rapidly, the speed of the truck will increase. So,
be careful.
③ When the truck travels on uneven ground, keep
the truck traveling at low speed.

Do not drive the forklift more than 30 minutes

without idling.
If the truck is driven 30 minutes, stop driving
and keep it 10 minutes under idle condition.
Excessive Driving may cause overheating of
brake and tires and this may result in short
life cycle of those parts.

5-20
(6) Stopping the truck
Η Press the brake pedal to stop the truck. Gear selector lever
Θ Put the gear selector lever in the neutral Parking brake switch
position.
Ι Press the parking brake switch.

250D7EOP14

Κ Lower the forks to the ground.

Low idling for

5 minutes

250D7EOP07

5-21
(7) Stopping engine
Gear selector lever
ö If the engine is abruptly stopped before it has Parking brake switch
cooled down, its service life may be
shortened. Avoid sudden stop except an
emergency.
ö When the engine is overheated, do not stop
immediately. Run the engine at a mid range
speed to allow it to cool down, then stop it.
Η Check if the parking brake is in the lock position.
Θ Check if the gear selector lever is in the neutral
position.
Ι Run the engine at low speed without
operating the equipment for about 5 minutes.
Turn the starting key to the OFF position and
remove the key. 5 minute
warming-up
(8) Checks after the engine stopped
Η Check the leakage of oil and water, the work
equipment and the exterior of the truck.
Θ Refill the fuel tank.
Ι Remove any debris inside of the engine room
and attached to the truck.

250D7EOP20

2) TRAVELING ON A SLOPE
Loaded
(1) Never travel down a slope in neutral.
(2) Lower the forks 15-20cm(6~8in) to the ground.
(3) Never turn on a slope, either loaded or unloaded.
(4) Never park on a slope.
(5) Loaded - move with forks upgrade
Unloaded - move with forks downgrade

ö Truck cannot travel effectively on a slope Unloaded

when the oil temperature is low. Do the
warming-up operation when it is going to
travel on a slope.
ö Be careful when working on slopes. It may
cause the truck to lose its balance and turn
over.

250D7EOP21

5-22
11. OPERATING SAFELY

Safe operation is the responsibility of the operator.

1) WATCH WHERE YOU ARE GOING. DON’T GO IF YOU CAN’T SEE...
(1) Before driving, check all around to be sure that your intended path of travel is clear of obstructions
and pedestrians.
LOOK WHERE YOU DRIVE. Watch out for pedestrians, other vehicles, obstructions
(especially overhead), and drop-offs. If the load blocks your view, drive backwards, except
up slopes.
(2) Do not allow anyone to stand or pass under the load or raised forks.
Watch for people in your work area even if your truck has warning lights or alarms. They may not
watch for you.
(3) Sound horn at intersections and wherever vision is obstructed.
Do not drive a truck up to anyone standing in front of an object.
2) PROTECT YOURSELF AND THOSE AROUND YOU...
(1) Operate the truck only from the designated operator’s position. Stay within the confines of the lift
truck profile dimensions. Keep all body parts inside the operator’s compartment and away from
the danger of passing obstructions. Keep inside the cabin.
ö A cabin is intended to offer protection 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, etc.
Keep clear of the mast and lift mechanism. NEVER reach into or put hands, arms, legs, or
head into or through the mast structure or near the carriage or lift chains. Never put any part
of your body between the mast and the truck.
Don’t use the mast as a ladder.
Keep all other persons clear of the load and mast mechanism while attempting to handle a
load.
3) NO RIDERS...
(1) Do not carry passengers. The operator is the only one who should be on the truck.
4) ALWAYS BE IN FULL CONTROL OF YOUR LIFT TRUCK...
(1) Never operate a lift truck or its attachments if you are not in the designated operator’s position.
(2) Never operate a lift truck when your hands and feet are wet or greasy.
(3) Always pick the smoothest travel route for your lift truck. Avoid bumps, holes, slick, spots, and
loose objects or debris in your path that may cause the truck to swerve or tip. If these conditions
are unavoidable, slow down and carefully drive past them. Slow down for wet or slippery surfaces.
(4) Avoid any sudden movement, it can cause the truck to tip-over.
Start, stop, travel, steer, and brake smoothly.
(5) Operate your lift truck under all conditions at a speed that will permit it to be brought safely to a
stop.

5-23
(6) Travel with the fork carriage tilted back and raised only enough to fully clear the ground or
obstacles. When the carriage(load) is in an elevated position the stability of the truck is reduced.
(7) Do not elevate the load except during stacking.
5) GRADES, RAMPS, AND INCLINES...
(1) Use special care when operating on ramps, inclines, and uneven areas. Travel slowly. Travel
straight up and down. Do not turn or drive at an angle across an incline or ramp. Do not attempt to
operate on grades in excess of those specified and/or recommended by the manufacturer.
(2) When the truck is loaded, travel with the load upgrade. When the truck is empty, travel with lifting
mechanism(mast) downgrade.
(3) Always brake with the right foot pedal(Not with the inching pedal) when travelling down incline.
If you should travel down incline for long distance, apply the engine brake with lower gear. Brake
mal-function such as performance drop, excessive wear of friction material and disc stick can be
caused by continuous brake operation making the oil overheating. In that case, stop traveling,
apply parking brake with neutral gear position and stay during 10 minutes with engine idle speed.
Do not travel down incline with neutral gear state.
It makes the brake oil overheated due to excessive brake operation.
6) PRACTICE SAFE OPERATION EVERY TIME YOU USE YOUR TRUCK...
(1) Careful driving and operation is your responsibility. Be completely familiar with all the safe driving
and load handling techniques in this Operator’s Manual. Use common sense. Drive carefully do
not indulge in stunt driving or horseplay. Observe traffic rules. Watch for people and hazards. Slow
down, be in full control of your lift truck at all times.
(2) Follow the instructions in this manual to avoid damage to your truck or the possibility of injury to
yourself of others.
(3) During your work, observe all functions of your lift truck. This allows you to immediately recognize
a problem or irregularity that could affect the safe operation of your truck.
(4) Periodically check the gauges and warning indicator lights in the instrument panel to be sure they
indicate a normal condition. If an abnormal condition appears bring the truck to a safe condition
and safe location, shut off the starting switch immediately and report the problem.
Do not continue to operate a truck that has a malfunction. Stop and have it fixed.
Always wear your seat belt when operating your truck.

5-24
12. LOAD HANDLING

1) GENERAL
Handle only loads that are within the truck rated capacity as shown on the nameplate. This rating
specifies the maximum load that should be lifted. However, other factors such as special load
handling attachments, load having a high center of gravity, or uneven terrain may dictate that the
safe working load be less than the rated capacity. Under these conditions, the operator must reduce
the load carried so that the lift truck remains stable.
Handle only stable or safely arranged loads. Do not handle loads made up of loose, unevenly
stacked, or unstable items that can easily shift and fall. Take the time to correctly stack and hand
loose items. Center the load on the forks.
Do not lift anything that might fall on the operator or a bystander. Do not handle loads that are
higher than the fork carriage unless the load is secured so that no part of it can fall backward.
Keep the load back against the LBR. Loads placed out on the ends of the forks can make the lift
truck less stable and more likely to tip up.
Lift and lower with the mast vertical or tilted slightly back-never tilted forward.
Operate lift and tilt controls slowly and smoothly. Never tilt the mast forward when the carriage(load)
is raised, 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
malfunctions in any way or becomes stuck in a raised position, operate the lift control to
eliminate any slack chains by raising the carriage. DO NOT go under a raised mast or forks
to attempt repairs.
DO NOT climb the mast or the truck.
Remember your truck is designed to carry loads forward of the front wheels so that the weight of
the load is counterbalanced by the weight of the truck.
The farther the load is carried from the pivot point(Center of front wheels), the less the weight on the
steer wheels. Therefore, always carry the load as close to the front wheels as possible(Back and
flush against the face of the forks.)
The capacity load shown on the nameplate is represented by a cube in weight is evenly distributed,
with the center of gravity located a standard distance from the face of the forks. If the weight of the
actual load to be handled is not evenly distributed, put the heaviest part closest to the carriage.

5-25
2) ADJUSTING THE LOAD FORKS
The load forks are adjustable on the hanger, carriage. Forks
should be spaced as far apart as the load will allow. Both forks
should always be the same distance from the center of the fork
carriage. To adjust the forks, raise the carriage slightly. Tilt the mast
fully forward to reduce friction and make the fork slide easier.
Unlock the fork locking pins.
Position the forks by pushing them away from you. Secure the fork
160D7OM134 locking pins.

3) LOAD ON FORKS

Do not elevate the load with one fork.
Loading with one fork cause the tip over, serious injury or death of
operator.
The work can cause the height difference between both fork tips.

D507OM137


Do not elevate the load with the ends of the forks.
This work can cause the height difference tips due to overload in
the end of the forks.
The load should be loaded at least over 2/3 of fork length.

D507OM138

5-26
4) TRAVELING WITH LOAD
Travel with load or carriage as low as possible and tilted back. Never travel with the load or carriage
raised(elevated) in a high position. Do not elevate the load except during stacking.
Observe all traffic regulations and watch for other traffic, pedestrians, and safe clearances. Always
look in the direction of travel. Keep a clear view of the path of travel and when the load blocks your
visibility, travel in reverse with load trailing(Except when climbing an incline).
Avoid sudden movements when carrying a load-start, stop, travel, steer, and brake smoothly. Steer
clear of bumps, holes, and loose materials or debris on the ground. Lift and tilt slowly and smoothly.
Go slowly when turning. Cross railroad tracks slowly and at an angle wherever 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 truck and load as you travel. Raise the forks or attachment only to
pick up or stack a load. Look out for obstructions, especially overhead.
Be aware that exaggerated tail swing, when turning while traveling forward, is a characteristic of lift
trucks that are steered by the rear wheels. Accordingly, you need to become accustomed to tail
swing and always check the tail swing area of the counterweight to be sure i is clear before you
turn.
Always be concerned about the stability of your lift truck. When attachments are used, extra care
should be taken in securing, manipulating, positioning, and transporting the load. Because
attachments generally add extra weight and complexity to the truck, operate trucks equipped with
attachments as partially-loaded trucks when not handling load.

5-27
5) PICKING UP AND MOVING LOADS
When picking up a load from the ground, approach the load
slowly and carefully align the truck square with the load. The
forks should be adjusted to fit the load or pallet being handle
and spread as wide as possible to provide good stability and
balance. Before lifting, be sure the load is centered and the
forks are fully under and supporting the load. Fork length
should be at least 2/3 of load length. With the lift and tilt
controls, adjust the forks to the correct height and angle for
freely engaging the load pallet. Move forward until the forks are
squarely and completely under the load.
Be Sure that the forks do not extend beyond the load,
causing damage or tipping of other adjacent loads or
250D7EOM136 materials behind the load being moved.
If the forks are longer 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 down and move forward until the load is positioned against the
carriage.
Raise the load from the ground or stack by tilting the mast back just enough to lift the load from the
surface. When stacking or tiering, use only enough backward tilt to stabilize the load.
Then raise the load to traveling height and tilt fully back to travel(Except for loads that must be
transported as level as possible).
6) UNLOADING
To deposit a load on the floor after being moved into the correct position, tilt the mast forward to a
vertical position and lower the load.
Adjust the fork height and tilt the mast forward slightly, as necessary, for smooth removal of the forks
from the load(Pallet).
Carefully back away to clear the forks from the load.
Raise the forks to traveling height and tilt forks to a level position 150~200mm(6~8in) off the floor.

5-28
7) STACKING
(1) To put a load on a stack
Η Approach slowly and align the lift truck and load squarely with
the stack.

D35AOM137

Θ Raise the load as the lift truck nears the stack.

D35AOM138

Ι Move forward slowly until the load almost touches the stack.
The leading edge and sides of the load pallet should line up
exactly with the near edge and side of the load or rack on
which you are stacking.

D35AOM139

Κ Stop close to the stack and further 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.
Λ When the load is aligned with the stack beneath it, tilt the mast
to the vertical position and carefully lower the load onto the top
D35AOM140
of the stack.

Μ Lower the forks slightly to clear the load pallet. Tilt the forks
forward slightly, if necessary.

D35AOM141

Ν Check your travel path, then carefully back away until the forks
are clear of the stack. Stop and lower the forks to the travel
position[150~200mm(6~8in) above the ground], then tilt back for
travel.

D35AOM142

5-29
(2) To move a load from a stack
Approach the stack carefully, truck lined up squarely with the load. With mast vertical, raise the
forks to the correct height for freely engaging the load pallet. Adjust fork angle as necessary to fit
squarely under the load. Move (inch) forward until the forks are under the load.
Be sure that the forks do not extend beyond the load, causing damage or tipping of other
adjacent loads or materials behind the load being moved. If the forks are longer than the load,
move the tips partially under the load without extending beyond the load.
Raise the load to clear the under surface. Back out several inches, then set the load 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 stack by tilting the mast back just enough to lift the load from the surface.
Or, with the mast still vertical, raise the forks until they begin to lift the load. at this point, apply the
minimum back tilt that will stabilize the load.
Check your travel path, slowly back up until clear of the stack, stop, and then lower the load to the
travel position [150~200mm(6~8in) off the ground]. Tilt full back to travel(Except for certain loads
that may have to be transported as level as possible). Be sure the load is back flush against the
carriage or front face of the forks.
ö Certain loads must be transported as level as possible.

5-30
13. SHUT DOWN PROCEDURE

ö Always leave your lift truck in a safe condition.

1) WHEN YOU LEAVE YOUR TRUCK, OR PARK IT, FOLLOW THESE SAFELY RULES
(1) Park in a safe area away from normal traffic.
(2) Never park on a grade or a slope.
(3) Never park in areas that block emergency routes or equipment, access to fire aisles, or stairways
and fire equipment.
2) BEFORE LEAVING THE OPERATOR’S POSITION
(1) Bring the truck to a complete stop.
(2) Put the directional control lever in the NEUTRAL position.
(3) Turn parking switch ON.
(4) Lower the lifting mechanism-carriage and forks or attachment fully to the ground.
3) IN ADDITION, WHEN LEAVING THE TRUCK
UNATTENDED
ON
(1) Tilt the mast forward until the forks are level and

P
flat on the ground. Let the engine run at idle
speed. Parking switch ON
(2) Turn the starting switch to the OFF position and
remove the key.
(3) Block the wheels, if the truck must be left on an
incline or you have any doubt about the truck
moving from a safe position.
ö If the lift truck has been working hard, let the
engine idle a few minutes before shutting it
250D7EOM31
off.

CAUTION FOR TURBOCHARGER PROTECTION

In order to prevent turbocharger failure, please
let the engine idle for more than 5 minutes
before shutting it off. Low idling for
5 minutes

250D7EOP07

5-31
14. STORAGE
1) BEFORE STORAGE
When you keep your forklift truck in storage for an
4
extended period of time, observe the following
safeguard instruction:
(1) Wash and tidy the truck and house it in a dry 3
building.
1
(2) When the truck has to be placed outdoors, park 2

it on a even ground and cover it securely with

canvas.
5 3 6
(3) Give enough fuel, grease, lubricant and oil.
(4) Coat exposed piston rods of all hydraulic 1 Adjust cylinder(2EA)
cylinders fully with grease. 2 Fork(2EA)
3 Tilt cylinder(Left/Right, 2EA)
(5) Cover batteries after removing terminals, or 4 Lift chain(2EA)
remove battery from the truck and store 5 Mast support(Left/Right, 2EA)
separately. 6 Steering axle(5EA)
250D7EOP17
(6) When the atmospheric temperature is
anticipated to drop below 0ç, add antifreeze.
(Refer to COLD WEATHER OPERATION about
ratio of water and antifreeze.)

2) DURING STORAGE Lubrication

operation once
(1) Operate the engine and move the truck for a a month
short 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 open. If they have to be performed inside
a building, open the windows and doors to
improve ventilation.
250D7EOP22
This is to avoid the danger of gas poisoning.

ö BATTERY
刮 Once a month, start the engine for 15 minutes (or use a charger) to charge the battery.
刯 Every 2 months, check the battery voltage and keep battery voltage over 25.08V.
到 If the machine stock period is over 6 months, disconnect the battery negative (-) terminal.

3) AFTER STORAGE
After storage(When it is kept without cover or the rust-preventive operation once a month is not
carried out), you should apply the following treatment before operation.
(1) Remove the drain plugs from the oil pan and other cases and drain any water.
(2) Remove the rocker housing cover and lubricate the valves and rocker arms well. Inspect the
valve operation.
(3) After the engine is started, run it at idling speed until it is warmed up completely.

5-32
15. TRANSPORT

1) PRECAUTIONS FOR LOADING AND UNLOADING

Contact your HYUNDAI forklift distributor for advice regarding transportation of the truck.
When loading or unloading the truck on or from a transporter, using loading ramp, the following
precautions must always be observed.
Check travel route for overpass clearance.
Make sure there is adequate clearance if the lift truck being transported is equipped with a
high mast or cab.
Remove ice, snow or other slippy material from the shipping lift truck and the loading dock.
(1) Ensure that the transporter cannot move by applying the brake and putting blocks under the
wheels. Place the transmission control in NEUTRAL.
(2) Fix the loading ramps securely so that the
centers of the transporter and truck are
aligned.(The loading ramps should be of
sufficient width, length and thickness to permit
safe loading or unloading.)
(3) After checking that the truck is aligned with the
loading ramps, back the truck slowly up the
ramps to load it on the transporter. D255OM33

When on the loading ramps, never change

direction. If it is necessary to change
direction, drive off the ramp and realign the
truck.
Block the wheels and secure the lift truck with
tiedowns.

250D7OM34

5-33
16. LOADING AND UNLOADING BY CRANE

1) Check the specification of the truck when you are

going to hoist the truck.
2) Use long wire rope and stay to keep the distance Wire rope
Stay
with the machine as it should avoid touching with
the truck body.
To lift

150~200mm
3) Put a rubber plate where the wire rope contact bracket

(6~8in)
with the truck's body to prevent damage.
4) Place crane on the proper place.
5) Install the wire rope and stay like the illustration.
Make sure wire rope is proper size.
Make sure that the truck is shut down and
safety lock lever is OFF before hoisting. Lifting Wire rope
the truck with engine running can cause Stay
serious accident.
The wrong hoisting method or installation of
wire rope can cause damage to driver and
truck.
Do not load abruptly.
Keep area clear of personnel.
Recommend to manufacture the stays REAR VIEW

separately as per lifting conditions. 250D7OM62A

Do not install the wire to unsafe position such

as forks, carriage, head guard, counterweight
lifting hole or towing pin, etc.. It can cause
X
Carriage(X) Counterweight
serious injury or damage to driver and truck. Head lifting hole(X)
guard(X)
If there is any problem to lift a truck, please
contact your dealer.
Perform the lifting service with skilled service Towing
pin(X)
men. Fork(X)
250D7OM63

5-34
 6. EMERGENCY STARTING AND TOWING
1. HOW TO TOW A DISABLED TRUCK

If your lift truck becomes disabled but it can be moved freely on its own wheels without further
damage, use the following procedures to tow it safely to a repair area.
It is important for your safety and the care of your lift truck to use the proper equipment and
carefully follow these recommendations for safe towing.
DO NOT tow a lift truck if there is a problem with the brakes or tires or the steering cannot be
operated. DO NOT tow up or down ramps and steep inclines. DO NOT attempt to tow a lift
truck if traction or weather conditions are poor.
1) Be sure to apply the parking brake or block the drive wheels on the disabled truck while working
around it.
2) When possible, raise the carriage(forks) on the disabled truck about 300mm(12in) from the floor or
ground. Secure the carriage with a chain.
3) Obtain another lift truck of equal or larger size carrying a partial load for traction.
4) Check that the counterweight bolts are in place and properly torqued.(This bolt is made of a special
high tensile steel and is not commercially available. Replace it, when necessary, only with a
genuine HYUNDAI replacement part).
5) Use an approved, solid metal tow bar with towing couplers that connect to the towing pins in the
counterweights.
6) Release the parking brake on the towed vehicle.
7) Transmission control is in neutral.

250D7EOM144

8) Tow the disabled truck backward. An operator must be on the towed truck.
Tow the truck slowly. Careful towing is necessary to prevent injury to personnel or damage to the
truck. The truck should be towed at a speed of less than 8km/h(5mph) with a driver in the seat. Do
not lift the truck or any wheels off the floor or ground while the truck is being towed.
The power steering will not operate on the disabled truck when the engine is not running.

6-1
9) Park the disabled truck in authorized areas only. Fully lower the forks to the floor, put the directional
control lever in the NEUTRAL position and turn the staring switch to the OFF position. Turn on the
parking brake switch. Remove the key and, when necessary, block the wheels to prevent the truck
from rolling.

Lift truck parking

250D7EOM32

Always engage the parking brake when parking a lift truck. The truck can move and cause
injury or death to personnel near it.

6-2
2. HOW TO USE BATTERY JUMPER CABLES

If your lift truck battery is discharged(dead), you can start your lift truck by Jumping it from another lift
truck that has a 24V negative-ground electrical system. The "Booster" battery must be fully charged
and in good condition. This section explains how to perform this procedure safely. To avoid damage
to your lift truck and your battery or the possibility of harm to yourself, follow the instructions and
warnings carefully. If you have any doubts, ask for help from an experienced mechanic.
If your truck has a battery with terminals on the side you will need a set of jumper cables with
matching connector clamps or cable adapters for side mounted battery terminals.
Use only a 24V NEGATIVE GROUND SYSTEM to jump your truck. You can injure yourself
and permanently damage your truck's 24V starting motor and ignition system by connecting it
to a 24V power supply or to a positive ground system.
BATTERIES CONTAIN SULFURIC ACID. Avoid acid contact with skin, eyes, or clothing. If
acid contacts your eyes or skin, flush immediately with water and get medical assistance.
Wear safety glasses when working near the battery to protect against possible splashing of
the acid solution.
1) If the discharged battery has filler caps, check the fluid level. Do not use an open flame to check
and do not smoke. If low, add distilled water to the correct level. Be sure to install the caps before
jump starting.
2) Do not jump start, charge, or test a sealed type battery if the test indicator looks illuminated or has a
bright color. Install a new battery.
BATTERIES EMIT EXPLOSIVE GAS. Do not smoke or have open flames or sparks in
battery charging areas or near batteries. An explosion can result and cause injury or death.
Hydrogen gas is produced during normal battery operation.
Hydrogen can explode if flames, sparks, or lighted tobacco are brought near the battery.
When charging or using a battery in an enclosed space, always provide ventilation and shield
your eyes. Wear safety glasses when working around batteries.
3) Put the truck with the booster battery as near to the other truck as necessary for the jumper cables
to reach both batteries. Check and make sure that the trucks do not touch each other. Use
particular care when connecting a booster battery to prevent sparks.
4) On both trucks:
Η Apply the parking brake.
Θ Put the directional control lever in the NEUTRAL position.
Ι Turn the starting switch to the OFF position.
Κ Turn all accessories to the OFF position and leave them off until after the engine has been
started and the jumper cables have been removed.
To avoid short circuits, remove all jewelry and do not permit any metal tools to make contact
between the positive battery terminal and other metal on the truck. When you connect
jumper cable clamps to the positive terminals of the two batteries, make sure that neither
clamp contacts any other metal. Injury can occur from electrical shock or explosion.

6-3
 5) Connect the jumper cables in the following
To ground sequence:
To starter switch
ͽ Connect a jumper cable from the
Charged battery
positive(+; red) terminal on one battery to
the positive(+; red) terminal on the other
- + - + battery. Never connect positive(+; red) to
b a negative(-; black), or negative to positive.
; Connect one end of the second cable to
the grounded negative(-; black) terminal of
Jumper
cable the Jumper vehicle battery.
Ϳ Connect the other end of the second
cable to a stationary, solid metallic point
c a on the engine of the Stalled vehicle, not
- + - + to the negative(-; black) terminal of its
Eng
block or battery. Make this connection at a point at
frame least 450mm(18in) away from the battery, if
Dead battery
possible. Do not connect it to pulleys, fans
To ground To starter switch
D35AOM146
or other parts that move. Do not touch hot
manifolds that can cause sever burns.
6) Start the engine on the Jumper vehicle and
run the engine at a moderate speed for a
minimum of five minutes.
7) Start the engine on the Stalled vehicle.
Follow the starting instructions in section 5,
Starting and Operating Procedures in this
manual. Be sure that the engine is at idle
speed before disconnecting the jumper
cables.
8) Remove the jumper cables by reversing the
installation sequence exactly. Start by
removing the last jumper cable from the
stalled vehicle first. Remove the cable end
from the engine block first, then the other end
of the negative(-; black) cable.
9) Remove both ends of the positive(+; red)
cable.

6-4
 7. PLANNED MAINTENANCE AND LUBRICATION
1. INTRODUCTION

ONLY TRAINED AND AUTHORIZED PERSONNEL should perform planned maintenance.

Local HYUNDAI dealers are prepared to help customers put in place a planed maintenance
program for checking and maintaining their lift trucks according to applicable safety
regulations.
Powered industrial trucks may becomes hazardous if maintenance is neglected.
As outlined in section 4, operator maintenance and care, the operator should make a safety
inspection of the lift truck before operating it. The purpose of this daily examination is to check for
any obvious damage and maintenance problems, and to have minor adjustments 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 inspection program. Performed on a regular basis
by trained personnel, the program provides through truck. The PM identifies needed adjustments,
repairs, or replacements so they can be made before failure occurs. The specific
schedule(frequency) for the PM inspections depends on the particular application and lift truck
usage.
This section recommends typical planned maintenance and lubrication schedules for items
essential to the safety, life, and performance of the truck. It also outlines safe maintenance
practices and gives brief procedures for inspections, operational checks, cleaning, lubrication, and
minor adjustments.
Specifications for selected components, fuel, lubricants, critical bolt torques, refill capacities, and
settings for the truck and found in section 9.
If you have needed for more information on the care and repair of your truck, see your HYUNDAI
dealer.

7-1
2. SAFE MAINTENANCE PRACTICES

The following instructions have been prepared from current industry and government safety standards
applicable to industrial truck operation and maintenance. These recommended procedures specify
conditions, methods, and accepted practices that aid in the safe maintenance of industrial trucks.
They are listed here for the reference and safety of all workers during maintenance operations.
Carefully read and understand these instructions and the specific maintenance procedures before
attempting to do any repair work. When in doubt of any maintenance procedure, please contact your
local HYUNDAI dealer.
1) Powered industrial trucks can become hazardous if maintenance is neglected. Therefore, suitable
maintenance facilities and trained personnel and procedures shall be provided.
2) Maintenance and inspection of all powered industrial trucks shall be performed in conformance with
the manufacturer's recommendations.
3) Follow a scheduled planned maintenance, lubrication, and inspection system.
4) Only trained and authorized personnel are permitted to maintain, repair, adjust, and inspect
industrial trucks and must do so in accordance with the manufacturer's specifications.
5) Always wear safety glasses. Wear a safety(hard) hat in industrial plants and in special work areas
where protection is necessary and required.
6) Properly ventilate work area, vent exhaust fumes, and keep shop clean and floors dry.
7) Avoid fire hazards and have fire protection equipment present in the work area. Do not use an
open flame to check for level or leakage fuel, electrolyte, or coolant. Do not use open pans of fuel
or flammable cleaning fluids for cleaning parts.
8) Before starting work on truck.
(1) Raise drive wheels free of floor and use oak blocks or other positive truck positioning devices.
(2) Remove all jewelry(watches, rings, bracelets, etc.).
(3) Put oak blocks under the load engaging means, inner masts, or chassis before working on them.
(4) Disconnect the battery ground cable (-) before working on the electrical system.
ö Refer to the jacking and blocking section in the service manual for proper procedures.
9) Operation of the truck to check performance must be conducted in an authorized, safe, clear area.
10) Before starting to operate the truck.
(1) Be seated in a safe operating position and fasten your seat belt.
(2) Make sure parking brake is applied.
(3) Put the direction control in NEUTRAL.
(4) Start the engine.
(5) Check functioning of lift and tilt systems, direction and speed controls, steering, brakes, warning
devices, and load handling attachments.

7-2
11) Before leaving the truck.
(1) Stop the truck.
(2) Fully lower the load-engaging means: mast, carriage, forks or attachments.
(3) Put the directional control in NEUTRAL.
(4) Apply the parking brake.
(5) Stop the engine.
(6) Turn the key switch to the OFF position.
(7) Put blocks at the wheels if the truck must be left on an incline.
12) Brakes, steering mechanisms, control mechanisms, warning devices, lights, governors, lift overload
devices, lift and tilt mechanisms, articulating axle stops, load backrest, CAB and frame members
must be carefully and regularly inspected and maintained in a safe operating condition.
13) Special trucks or devices designed and approved for hazardous area operation must receive
special attention to insure that maintenance preserves the original approved safe operating
features.
14) Fuel systems must be checked for leaks and condition of parts. Extra special consideration must
be given in the case of a leak in the fuel system. Action must be taken to prevent the use of the
truck until the leak has been corrected.
15) All hydraulic systems must be regularly inspected and maintained in conformance with good
practice. Tilt and lift cylinders, valves, and other parts must be checked to assure that drift or
leakage has not developed to the extent that it would create a hazard.
16) When working on the hydraulic system, be sure the engine is turned off, mast is in the fully-lowered
position, and hydraulic pressure is relieved in hoses and tubing.
Always put oak blocks under the carriage and mast rails when it is necessary to work with the
mast in an elevated position.
17) The truck manufacturer's capacity, operation, and maintenance instruction plates, tags, or decals
must be maintained in legible condition.
18) Batteries, limit switches, protective devices, electrical conductors, and connections must be
maintained in conformance with good practice. Special attention must be paid to the condition of
electrical insulation.
19) To avoid injury to personnel or damage to the equipment, consult the manufacturer's procedures in
replacing contacts on any battery connection.
20) Industrial trucks must be kept in a clean condition to minimize fire hazards and help in detection of
loose or defective parts.
21) Modifications and additions that affect capacity and safe truck operation must not be done without
the manufacturer's prior written approval. This is an OSHA requirement.
Capacity, operation, and maintenance instruction plates, tags, or decals must be changed
accordingly.

7-3
22) Care must be taken to assure that all replacement parts, including tires, are interchangeable with
the original parts and of a quality at least equal to that provided in the original equipment. Parts,
including tires, are to be installed per the manufacturer's procedures. Always use genuine
HYUNDAI or HYUNDAI-approved parts.
23) When removing tires follow industry safety practices. Most importantly, deflate pneumatic tires
completely prior to removal. Following assembly of tires on multi-piece rims, use a safety cage or
restraining device while inflating.
24) Use special care when removing heavy components, such as counterweight, mast, etc.. Be sure
that lifting and handling equipment is of the correct capacity and in good condition.

7-4
3. INSTRUCTIONS BEFORE MAINTENANCE

1) INTERVAL OF MAINTENANCE
(1) You may inspect and service the machine by the
period as described at based on service meter of
LCD.
(2) Shorten the interval of inspect and service
depending on site condition.(Such as dusty area,
quarry, sea shore and etc.)
(3) Practice the entire related details at the same
time when the service interval is doubled.
For example, in case of 250 hours, carry out all
the maintenance each 250hours, each 100hours
and daily service at the same time. 160D7ECD131

ö Time intervals between maintenances are largely determined by operating conditions. For
example, operation in sandy, dusty locations requires shorter maintenance intervals than operation
in clean ware-houses. The indicated intervals are intended for normal operation. The operating
condition classifications are ;
 NORMAL OPERATION
Eight hour material handling, mostly in buildings or in clean, open air on clean paved surfaces.
 SEVERE OPERATION
Prolonged operating hours or constant usage.
 EXTREME OPERATION
- In sandy or dusty locations, such as cement plants, lumber mills, and coal dust or stone crushing
sites.
- High-temperature locations, such as steel mills and foundries.
- Sudden temperature changes, such as constant trips from buildings into the open air, or in
refrigeration plants.
- If the lift truck is used in severe or extreme operating conditions, you must shorten the
maintenance intervals accordingly.
ö Since the operating environment of lift trucks varies widely, the above descriptions are highly
generalized and should be applied as actual conditions dictate.

7-5
2) PRECAUTION
(1) Start maintenance after you have the full knowledge of machine.
(2) The monitor installed on this machine does not entirely guarantee the condition of the machine.
Daily inspection should be performed according to maintenance.
(3) Engine and hydraulic components have been preset in the factory.
Do not allow unauthorized personnel to reset them.
(4) Ask to your local dealer or Hyundai for maintenance advise it unknown.
(5) Drain the used oil and coolant in a container and handle according to the method of handling for
industrial waste to meet with regulations of each province or country.
3) PROPER MAINTENANCE
(1) Replace and repair of parts
It is required to replace the wearable and consumable parts such as hose, tube and filter etc.,
regularly. Replaced damaged or worn parts at proper time to keep the performance of machine.
(2) Use genuine parts.
(3) Use the recommended oil.
(4) Remove the dust or water around the inlet of oil tank before supplying oil.
(5) Drain oil when the temperature of oil is warm.
(6) Do not repair anything while operating the engine.
(7) Stop the engine when you fill the oil.
(8) Relieve hydraulic system of the pressure by opening of breather when repairing the hydraulic
system.
(9) Confirm if the cluster is in the normal condition after completion of service.
(10)For more detail information of maintenance, please contact local Hyundai dealer.
ö Be sure to start the maintenance after fully understanding the section 1, safety hints.

4) PRECAUTION WHEN INSTALLING HYDRAULIC HOSES OR PIPE.

(1) Be particularly careful that joint of hose, pipe and functioning item are not damaged.
Avoid contamination.
(2) Assemble after cleaning the hose, pipe and joint of function item.
(3) Use genuine parts.
(4) Do not assemble the hose in the condition of twisted or sharp radius.
(5) Keep the specified tighten torque.

7-6
5) PERIODICAL REPLACEMENT OF SAFETY PARTS
(1) These are the parts which the operator cannot judge the remained lifetime of them by visual
inspection.
(2) Repair or replace if an abnormality of these parts is found even before the recommended
replacement interval.
ö Replacement of consumable service parts is not covered under warranty.

Periodical replacement of safety parts Interval

1 Fuel hose Every 2 to 4 years

2 Hydraulic pump hose Every 2 years
3 Power steering hose Every 2 years
4 Packing, seal, and O-ring steering cylinder Every 2 to 4 years
5 Lift chain Every 2 to 4 years
6 Lift cylinder 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

ö Replace the O-ring and gasket at the same time when replacing the hose.
ö Replace clamp at the same time if the hose clamp is cracked when checking and replacing
hose.

7-7
4. PLANNED MAINTENANCE INTERVALS

1) MAJOR COMPONENTS LOCATION

250D7EOM21

1 Mast 9 Transmission 17 Counterweight

2 Lift cylinder 10 Torque converter 18 Radiator
3 Steering unit 11 Engine 19 Seat
4 Tilt cylinder 12 Steering cylinder 20 Cabin
5 Main control valve 13 Hydraulic pump 21 Steering wheel
6 Fork 14 Steering axle 22 Muffler
7 Front wheel 15 Rear wheel 23 Propeller shaft
8 Drive axle 16 Air cleaner

7-8
 2) MAINTENANCE CHECK LIST
(1) EVERY 10 HOURS SERVICE
Check items Service Remarks
Visual inspection
·Truck for obvious damage and leaks. Check, Repair or Replace 7-14
·Warning plates and decals. Check, Replace 7-14
·Condition of tires and wheels. Air pressure. Check, Refill or Replace 7-16
·Lift chain and fastener. Check, Adjust 7-60
·Carriage or attachment and forks. Check, Repair or Replace 7-43
·Fuel level Check, Refill 3-6, 5-13
·Engine oil level Check, Refill 3-8, 7-19
·Coolant level(Radiator & reservoir tank). Check, Refill 7-21
·Water separator. Check, Clean 3-9, 7-29
·Hydraulic oil level. Check, Refill 7-32
·Fan belt damage Check, Replace 7-26
Function tests
·Horn and lamp Check, Repair or Replace 3-5
·Gauges and instrument panel. Check, Repair or Replace 3-5
·Warning light. Check, Repair or Replace 3-5
·Service brake and inching operation. Check, Repair or Replace 3-24
·Parking brake operation. Check, Repair or Replace 3-19
·Accelerator and engine speed operation. Check, Adjust 3-24, 10-4
·Directional and speed control operation. Check, Repair or Replace 3-24
·Steering wheel operation. Check, Repair or Replace 3-24
·Noise and vibration. Check, Repair or Replace 5-12

(2) EVERY 50 HOURS SERVICE

Check items Service Remarks
Air cleaner element Check, Clean 7-27
Air breather filter Check, Clean 7-34
Engine oil/filter (Initial 50 hours only) Change/Replace 7-19
Transmission oil level. Check, Refill 7-38
Lubrication
·Steering axle linkage pin Check, Clean, Lubricate -
·Hydraulic pump drive spline. Check, Clean, Lubricate -
Tightening torques
·Pump mounting bolt Check, Tight 8-4
·Drive axle mounting bolt Check, Tight 8-4
·Tilt cylinder mounting and yoke bolt Check, Tight 8-4
·Mast mounting bolt Check, Tight 8-4
·Drive & steering axle wheel mounting bolt & nut Check, Tight 8-4
·Counterweight mounting bolt Check, Tight 8-4
·Cabin mounting bolt Check, Tight 8-4
·Main pump & MCV mounting bolt Check, Tight 8-4
·Engine & radiator mounting bolt Check, Tight 8-4
·Transmission mounting bolt Check, Tight 8-4
·Steering axle mounting bolt Check, Tight 8-4

7-9
 (3) INITIAL 100 HOURS SERVICE
Check items Service Remarks
Differential gear oil Change 7-41
Transmission oil and filter Replace 7-38
Brake cooling oil Change 7-42

(4) EVERY 250 HOURS SERVICE

Check items Service Remarks
Differential gear oil Check, Refill 7-41
Lubrication
·Lift chain Check, Lubricate 7-60
·Mast roller and pin Check, Lubricate 7-60
·Lift cylinder rod end Check, Lubricate 7-60
·Lift cylinder tube end Check, Lubricate 7-60
·Tilt cylinder rod end Check, Lubricate 7-60
·Tilt cylinder tube end Check, Lubricate 7-60
·Steering cylinder rod end Check, Lubricate 7-60
·Steering cylinder tube end Check, Lubricate 7-60
·Attachment option cylinder rod end Check, Lubricate 7-60
·Attachment option cylinder tube end Check, Lubricate 7-60
·Steering axle wheel bearing Check, Lubricate 7-60
·Pedal pivot Check, Lubricate 7-60

(5) EVERY 500 HOURS SERVICE

Check items Service Remarks
Mast mounting bolt Check, Tight 8-4
Drive axle mounting bolt and nut Check, Tight 8-4
Air cleaner element(*1) Replace 7-27
Battery Check, Replace 7-47
Engine ignition and timing Check, Replace 5-11
Engine oil filter Replace 7-19
Engine oil Change 7-19
Coolant test (DCA4 concentration) Test, Add 7-24-1, 2
Coolant filter Replace 7-21

*1 When the air cleaner warning lamp is ON, replace the air cleaner element.

(6) EVERY 1000 HOURS SERVICE

Check items Service Remarks
Hydraulic oil return filter Replace 7-33
Hydraulic oil tank
·Hydraulic oil Change 7-33
·Suction strainer Replace 7-33
Transmission oil & filter Change 7-38
Differential oil Change 7-41
Fan belt tension and damage Replace 7-26
Brake cooling oil Change 7-42
Fuel filter Replace 7-28

7-10
 (7) EVERY 2000 HOURS SERVICE
Check items Service Remarks
Hyd suction strainer Replace 7-33
Radiator coolant Replace 7-33
Hydraulic oil(*2) Replace 7-33

*2 Conventional hydraulic oil

(8) EVERY 5000 HOURS SERVICE

Check items Service Remarks
Hydraulic oil(*3) Replace 7-33
*3 Hyundai genuine long life hydraulic oil

(9) WHEN REQUIRED

Check items Service Remarks
Fuel system
·Fuel tank Drain or Clean 7-27
·Water separator Drain or Clean 7-29
·Fuel filter Replace 7-28
Engine lubrication system
·Engine oil Replace 7-19
·Engine oil filter cartridge Replace 7-19
Engine cooling system
·Coolant Refill, Replace 7-21
·Radiator Clean 7-26
Engine air intake system
·Air cleaner element Replace 7-27
Hydraulic tank
·Hydraulic oil Refill or Replace 7-33
·Hydraulic oil suction strainer Check, Clean 7-33
·Return oil filter element Refill, Replace 7-33
·Air breather filter Refill, Replace 7-34
Hand pump(cabin tilt)
·Hydraulic oil Refill or Replace 7-18
Tire air pressure Check, Refill 5-3

7-11
5. MAINTENANCE CHART

1) MAINTENANCE LOCATIONS

14 1

15 2

16 3

17 4

18 5

28 6

20 7
8
21
19
22 9

23 10

24 11

25 12

26 13

27

180D7EMA011

CAUTION
ö Service intervals are based on the hourmeter reading.
ö Stop the engine when servicing.
ö Do not open the cap or drain plug to avoid injury by unexpected spouting of high temperature fluid
or gas.
ö Open the cap slowly to relieve pressure.
ö Always keep the surface of control & instrument panels clean in case of damage or malfunction
detected in panel, please it by a new one.
ö For other details, refer to the service manual.

7-12
 2) MAINTENANCE CHART
Service Item Service Oil Service
Description Capacity(ℓ)
interval No. Action symbol point No.
2 Pedal linkage Check, Adjust - - 1
3 Drive rim & Tire air pressure Check, Add - - 2
4 Horn operation Check, Replace - - 2
5 Lamp operation Check, Replace - - 10
8 Fuel level Check, Add DF 531 1
9 Water separator Check, Drain - - 1
10 Hours
11 Fan belt tension Check, Replace - - 1
or daily
12 Radiator coolant Check, Add C 30.6 1
13 Steer rim & Tire air pressure Check, Add - - 2
15 Lift chain Check, Lubricate EO - 2
16 Tilt pin & Mast roller Check, Lubricate G - 2
20 Engine oil level Check, Add EO 20 1
21 Hydraulic oil level Check, Add HO 268 1
Initial 20 Engine oil Change EO 20 1
50 Hours 25 Engine oil filter Replace - - 1
6 Transmission oil level Check, Add EO 32- 1
24 Air cleaner element Check, Clean - - 1
50 Hours
25 Engine oil filter Check, Clean G - 2
or weekly
26 Fan pulley drive Check, Lubricate - - 1
27 Steering axle linkage Check, Lubricate G 27.5+2×3.2 2
1 Axle gear oil(Differential+2×Hub) Change GO 27.5+2×3.2 1
Initial 6 Transmission oil Change EO 32 1
100 Hours 10 Brake cooling oil Change - 33+2 1
18 Transmission oil filter Replace - - 1
1 Axle gear oil(Differential+2×Hub) Check GO 33+2 1
10 Brake cooling oil Check - - 1
250 Hours 14 Forks Check - - 2
or monthly 15 Lift chain tension Check - - 2
16 Tilt pin & Mast roller Check, Lubricate G - 2
23 Hydraulic oil air breather element Check, replace - - 1
7, 24 Fuel filter, Air cleaner element Replace - - 1, 1
17 Mast mounting bolt Check, Tight - - 4
500 Hours
17 Drive axle mounting bolt and nut Check, Tight - - 8
or
3 monthly 19 Battery Clean - - 2
12 Coolant test(DCA4 concentration) Test, Add DCA4 - 1
25,12 Engine oil and filter, Coolant filter Change - 20, - 1,1
1 Axle gear oil(Differential+2×Hub) Change GO 27.5+2×3.2 1
6 Transmission oil Change EO 32 1
1000 Hours 10 Brake cooling oil Change - 33+2 1
or 11 Fan belt tension & Damage Check, replace - - 1
6 monthly 18 Transmission oil filter Replace - - 1
22 Hydraulic oil return filter Replace - - 1
28 Brake pressure filter element Replace - 30 1
12 Radiator coolant Replace C - 1
2000 Hours 21 Hydraulic strainer Check, Clean - 268 1
21 Hydraulic oil*1 Change HO 268 1
5000 Hours 21 Hydraulic oil*2 Change HO 1
*1 Conventional hydraulic oil *2 Hyundai genuine long life hydraulic oil
※ Oil symbol
Refer to the recommended lubricants for specification.
DF : Diesel fuel HO : Hydraulic oil EO : Engine oil GO : Gear oil
MO : Transmission oil BF : Break fluid C : Coolant G : Grease
7-13
6. HOW TO PERFORM PLANNED MAINTENANCE

1) VISUAL INSPECTION
First, perform a visual inspection of the lift truck
and its components. Walk around the truck and
take note of any obvious damage or maintenance
problems.
Check to be sure all capacity, safety, and warning
plates are attached and legible.
ö NAMEPLATES AND DECALS: Do not operate
a lift truck with damage or lost decals and 250D7EOM22
nameplates. Replace them immediately. They
contain important information.
Inspect the truck, before and after starting the
engine, for any sign of external leakage of fuel,
engine coolant, transmission fluid, etc..
Check for hydraulic oil leaks and loose fittings.
HYDRAULIC FLUID PRESSURE: Do not use
your hands to check for hydraulic leakage.
Fluid under pressure can penetrate your skin
and cause serious injury.
2) CABIN
Be sure that the driver's cabin 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.
3) LOAD HANDLING COMPONENTS
Inspect the mast assembly, load backrest(LBR),
rails, carriage rollers, lift chains, and lift and tilt
cylinders. Look for obvious wear and maintenance
problems and damaged or missing parts. Check 250D7EOM23
for any loose parts or fittings. Check for leaks,
damaged or loose rollers, and rail wear(metal
flaking). Carefully check the lift chains for wear,
rust, corrosion, cracked or broken links, stretching
etc.. Check that the lift and carriage chains are
correctly adjusted to have equal tension. Check
that the lift chain anchor fasteners and locking
means are in place and tight. Inspect all lift line
hydraulic connections for leaks.
Mast and lift chains require special attention
and maintenance to remain in safe operating
condition. Refer to lift chain maintenance in
this section for additional information.

7-14
4) FORKS
Inspect the load forks for cracks, breaks, bending,
and wear. The fork top surfaces should be level
and even with each other. The height difference 10% of "A" is
max. wear
between both fork tips refer to below table. allowed

Fork length (mm) Height difference (mm)

equal or below 1500 3 Height difference
above 1500 6

If the fork blade at the heel is worn down by D35AOM150

more than 10%, the load capacity is reduced

and the fork must be replaced.
Inspect the forks for twists and bends. Put a Shank

5cm(2in) thick metal block, at least 10cm(4in) wide 12.5mm MAX

by 61cm(24in) long with parallel sides, on the blade
of the fork with the 10cm(4in) surface against the
blade. Put a 61cm(24in) carpenter's square on the 600mm
Carpenter square
top of the block and against the shank. Check
Blade
the fork 51cm(20in) above the blade to make sure Metal block
it is not bent more than 12.5mm(0.5in) maximum.
160D7OM151
ö If the fork blades are obviously bent or
damaged, have them inspected by a trained
maintenance person before operating the
truck.
Inspect the fork locking pins for cracks or damage.
Reinsert them and note whether they fit properly.

7-15
5) WHEEL AND TIRES
Check the condition of the drive and steering
wheels and tires. Remove objects that are
embedded in the tread. Inspect the tires for
excessive wear and breaks or chunking out.
Check all wheel lug nuts or bolts to be sure none
are loose or missing. Replace missing bolts or lug
nuts. Torque loose or replaced items to D35AOM152
specifications.
Check tire pressure from a position facing the
tread of the tire, not form the side. Use a
long handled gauge to keep your body away
from the side. If tires are low, do not operate
and do not add air. Check with a mechanic.
The tire may require removal and repair.
Incorrect (low) tire pressure can reduce the
stability of your lift truck. Do not operate truck
with low tire pressure.
250D7EOM153
ÂProper cold inflation : Refer to attached decal.

7-16
6) TILTING CABIN
Keep clearance of people except the operator
before tilting the cabin.
Before tilting the cabin, make sure that the A
mast is vertical or tilted forward. Otherwise, the
operation could be blocked by mast tilt
cylinders. Cover(LH)

(1) Locate the truck on the plain and stable floor.

ö Apply parking brake before servicing.
(2) Turn the start switch to OFF position.
Remove the frame cover(LH) by removing the Lock lever
mounting bolts or opening the door. The control
switch is located between cabin and side frame. UP
STOP
(3) By tilting the cabin, service of hydraulic and DOWN

electric system such as hydraulic components, Control switch

hydraulic pipings, electric components, and DETAIL A
electric wirings can be easily performed. It is
recommended that the service requiring tilting
250D7EMA63
cabin must be carefully performed with a skilled
service man.

(4) Tilting the cabin back to normal position.

Η Turn the key switch(C) to ON position. Keep
pushing the downside of the switch(A) until the
cabin stops at the angle of 20Á
.
Θ Release the locking lever(B) and then keep
20
pushing the downside of the switch(A) again
until the cabin completely stops at the normal
position.
ö After finishing the work, cover(LH) must be
installed to prevent abnormal operation.
250D7EMI66

Do not operate cabin tilting function while the

power is ON or engine is running.
START
(X)

ON
(X)

OFF
(O)

160D7MI65

7-17
 Do not operate the tilt control switch or any
control parts while servicing under the tilted
cabin. It can cause severe injury or death.

WARN
DO
NOT
OPERATE

250D7EMI64

The angle of fully tilted cabin is 65。and the

safety lock function operates within the tilting
angle of 20。
. 65

20

250D7EMI68

(5) Replacement of hydraulic oil for hand pump.

HAND PUMP
Open upper cap and fill 0.8ℓ by using funnel. Cap 20mm
After filling, operate tilt cylinder 2~3 times and
Reservior Full
close the cabin completely to check the oil level
tank
in tank. If necessary, fill more oil to keep the
level.
·tank capacity : 0.7ℓ

Drain
250D7EMI67

7-18
7. SERVICE INSTRUCTION

1) CHECK ENGINE OIL LEVEL

Engine oil fill
Check the oil level with the machine on a flat
ground before starting engine.
(1) Pull out the dipstick and wipe with a clean cloth.
(2) Check the oil level by inserting the dipstick
completely into the hole and pulling out again.
(3) If oil level is LOW, add oil and then check again.
ö If the oil is contaminated or diluted, change
the oil regardless of the regular change
interval.
Normal
ö Check oil level after engine has been stopped
for 15 minutes.
Do not operate unless the oil level is in the Dipstick
normal range.
180D7EMI01

2) REPLACEMENT OF ENGINE OIL AND OIL

FILTER
(1) Operate the engine until the coolant temperature
reaches 60ÁC (140ÁF). Shut off the engine.
(2) Remove the plug and allow the oil to drain.
 Wrench size : 27mm
ö A drain pan with a capacity of 30 liters (6.6 Plug
U.S.gallons) will be adequate. Drain pan
180D7EMI02

(3) Clean the area around the oil filter head.

(4) Use oil filter wrench to remove the oil filter.
(5) Clean the gasket surface of oil filter head.
ö The O-ring can stick on the filter head; make
sure it is removed before installing the new
filter.

180D7EMI03

7-19
(6) Apply a light film of lubricating oil to the gasket
sealing surface before installing the filter. Oil
ö Fill the filter with clean lubricating oil before
installation.

7803A6MI07

(7) Install the filler to the filter head.

ö Mechanical over-tightening may distort the
threads or damage the filter element seal. O

180D7EMI10

(8) Clean and inspect the oil drain plug threads and
the seal surface. If any damage is found, the oil
drain plug must be replaced. Install and tighten
the oil drain plug.

Drain plug
180D7EMI04

(9) Fill the engine with clean oil to the proper level.
ÂQuantity : 20˶(5.3 U.S.gallons)

180D7EMI61

7-20
(10) Operate the engine at low idle and inspect for
leaks at the filter and the drain plug.
Shut the engine off and check oil level with
dipstick. Allow 15 minutes for oil to drain down
before checking.
ö Do not overfill the engine with oil.

180D7EMI05

3) CHECK COOLANT LEVEL

(1) Check the coolant level at reservoir tank.
(2) Add the mixture of antifreeze and water after if Max
coolant is not sufficient. Normal HY
UN
DA
I

Min
(3) The coolant level should indicate the middle FU
LOLL
position. W

(4) Replace gasket of radiator cap when it is

damaged. 160DOM61

Do not remove the radiator cap from a hot

engine. Wait until the coolant temperature is
below 50 Á C(120 Á F) before removing the OK NOT OK
radiator cap. Heated coolant spray or steam
can cause personal injury.
ö Do not add cold coolant to a hot engine ;
engine castings can be damaged. Allow the
engine to cool to below 50Á Á
C(120ÁF) before
adding coolant.

160D7EMI30

7-21
4) FLUSHING AND REFILLING OF RADIATOR
(1) Change coolant
Avoid prolonged and repeated skin contact
with used antifreeze. Such prolonged
repeated contact can cause skin disorders or
other bodily injury.
Avoid excessive contact-wash thoroughly
after contact.
Keep out of reach of children. 160D7EMI31

Protect the environment : Handling and

disposal of used antifreeze can be subject to
federal, state, and local law regulation.
Use authorized waste disposal facilities,
including civic amenity sites and garages
providing authorized facilities for the receipt of
used antifreeze.
If in doubt, contact your local authorities for
guidance as to proper handing of used
antifreeze.

Wait until the temperature is below 50Á Á

C
(120Á F) before removing the coolant system
radiator cap. Failure to do so can cause
personal injury from heated coolant spray.
Drain the cooling system by removing the plug
on the fuel tank and removing the plug in the
bottom of the water inlet.
A drain pan with a capacity of 45 liters (11.9
U.S.gallons) will be adequate in most
applications. 160D7MI07

(2) Flushing of cooling system

Η Fill the system with a mixture of sodium OK
carbonate and water(or a commercially
available equivalent).
ö Use 0.5kg (1.0pound) of sodium carbonate
for every 23 liters(6.0 U.S. gallons) of water.
ö Do not install the radiator cap. The engine is
to be operated without the cap for this
process.
7803AMI16

7-22
ö The system must be filled properly to
prevent air locks.
During filling, air must be vented from the
engine coolant passages. Wait 2 to 3
minutes to allow air to be vented; then add
mixture to bring the level to the top.
 Adequate venting is provided for a fill rate of 19
liters/minute (5 U.S.gal/minute).

Θ Operate the engine for 5 minutes with the

coolant temperature above 80°C (176°F).
Shut the engine off, and drain the cooling
system.

OFF

160D7EMI10

Ι Fill the cooling system with clean water.

ö Be sure to vent the engine and aftercooler
for complete filling.
ö Do not install the radiator cap or the new
coolant filter.

7803AMI38

Κ Operate the engine for 5 minutes with the

coolant temperature above 80°C(176°F).
Shut the engine off, and drain the cooling
system.
ö If the water being drained is still dirty, the
system must be flushed again until the water
OFF
is clean.

160D7EMI10

7-23
(3) Cooling system filling
ö The system must be filled properly to prevent
air locks.
During filling, air must be vented from the
engine coolant passages. Wait 2 to 3
minutes to allow air to be vented; then add
mixture to bring the level to the top.
 The system has a design fill rate of 19 liters per
minute (5 U.S.gallons per minute).

Η Use a mixture of 50 percent water and 50

percent ethylene glycol antifreeze to fill the
cooling system.
ö Coolant capacity(Engine only); 10.9˶(2.8
U.S.gallons)
ö Use the correct amount of DCA4 corrosion
inhibitor to protect the cooling system.

18036MI22

Θ Install the radiator 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
system is full of coolant.

NOT OK 160D7MI11

7-24
4) COOLANT TEST STRIPS INSTRUCTIONS
(1) Pre-test instruction
Recommended testing frequency - at every coolant
filter change interval.
① Collect coolant sample from the radiator drain
valve.
- Do not collect from the coolant recovery or
overflow system
- Coolant must be between 10~54℃ when test-
ed
- Room temperature is best.
② For accurate results, test must be completed within
75 seconds.
- Follow recommended test times. Use a stop-
watch.
③ Record and track results.

(2) Test instruction

① Remove one strip from bottle and replace cap
immediately. End pad A
Middle pad B
Do not touch the pads on the end of the strip. Top pad C
Discard kit if nitrite test pads of unused strips have
turned brown.
Test strip, prior to testing
② Dip strip for 1 second in coolant sample, remove,
and shake strip briskly to remove excess liquid.

③ 45 seconds after dipping strip, compare results to

color chart and record in the following order: % GLYCOL/FREEZEPOINT ( F) (End Pad)
25% 40% 50% 60%
for
+10 -3 -10 -20 -30 -45 -60 F

SCA UNITS PER GALLON

④ All three readings must be completed no later

than 75 seconds after dipping strip.
⑤ If uncertain about the color match, pick the low
numbered block.
ex.) If nitrite color is not F, use column E.
⑥ Determine where the molybdate level intersect
the nitrite level on the chart. The amount of SCA
units per gallon in the cooling system is given Row 0

where the molybdate row intersect the nitrite

column.

7-24-1
(3) Maintenance actions based on results
① Above normal
- Do not replace the coolant filter
or add DCA4 liquid until additive
concentration falls below 3 units
per gallon.
- Test at every subsequent coolant
filter change interval.
② Normal
- Continue to replace the coolant
filter at your normal interval.
③ Below normal
- Replace the coolant filter and add 1
pint of additive per each 4 gallons
of coolant.
- Replace the coolant filter and add
40 cc of additive per each 1 liter of
coolant.
※ If you need part number of Test kit or DCA4, please
see Parts Manual.

7-24-2
5) CLEAN RADIATOR AND OIL COOLER
NOT OK
Check, and if necessary, clean and dry outside of
radiator and oil cooler. After working in a dusty
place, clean radiator more frequently.
(1) Visually inspect the radiator for clogged radiator
fins.
550kPa
(80psi)
(2) Use 550kPa(80psi) air pressure to blow the dirt
and debris from the fins.
7803AMI39
Blow the air in the opposite direction of the fan air
flow.
(3) Visually inspect the radiator for bent or broken
fins.
ö If the radiator must be replaced due to bent or
broken fins which can cause the engine to
overheat, refer to the manufacturer's
replacement procedures.
(4) Visually inspect the radiator for core and gasket
leaks.
7803AMI40

6) DRIVE BELT
(1) Inspect the belts daily. Check the belts for OK
intersecting cracks. Transverse(across the belt
width) cracks are acceptable.
Longitudinal(direction of belt length) cracks that
intersect the transverse cracks are not
acceptable. Replace a belt if it is frayed or has
NOT OK
pieces of material missing.
73036MI23

7) INSPECTION OF COOLING FAN

Personal injury can result from a fan blade

failure. Never pull or pry on the fan. This can
damage the fan blade and cause fan failure.
ö Rotate the crankshaft by using the engine
barring gear.
NOT OK
ö A visual inspection of the cooling fan is
required daily.
Check for cracks, loose rivets, and bent or 21076MI10B
loose blades.
Check the fan to make sure it is securely
mounted. Tighten the capscrews if necessary.
Replace any fan that is damaged.

7-25
8) BELT TENSIONER, AUTOMATIC ADJUSTMENT
(1) Every 1000hours, or 1 year, whichever occurs first,
inspect the automatic belt tensioner.
With the engine turned off, check that neither the
top nor bottom tensioner arm stop is touching the
cast boss on the tensioner body. If either of the
stops is touching a boss, the alternator belt must be
replaced. Check to make sure the correct belt part
number is being used it either condition exists. 7807AMI50

(2) Check the tensioner pulley and body for cracks.

If any cracks are noticed, the tensioner must be
replaced. Refer to a Cummins Authorized
Repair facility. Check the tensioner for dirt
buildup. If this condition exists, the tensioner
must be removed and steam-cleaned.

7807AMI51

(3) Check that the bottom tensioner arm stop is in

contact with the bottom tensioner arm stop boss
on the tensioner body. If these two are not
touching, the tensioner must be replaced.

7807AMI52

(4) Inspect the tensioner for evidence of the pivoting

tensioner arm contacting the stationary circular
base. If there is evidence of these two areas
touching, the pivot tube bushing has failed and
the tensioner must be replaced.

7807AMI53

7-26
(5) A worn tensioner that has play in it or a belt that
“walks” off its pulley possibly indicates pulley
misalignment.
ö Maximum pulley misalignment is three
degrees. This measurement can be taken
with a straightedge and an inclinometer.
(6) Install the belt.

7807AMI54

9) CLEANING OF AIR CLEANER

Clamp
(1) Primary element
Η Remove the cover by pulling off the clamps and
loosen the wing nut to pull out the outer
element.
Θ Clean the inside of the body.
Ι Clean the element with pressurized air.
ÂRemove the dust inside of the element by the
pressurized air(Below 3kgf/cm2, 40psi) forward
and backward equally. Pressurized air
Κ Inspect for cracks or damage of element by
2
3kgf/cm below
putting a light bulb inside of the element.
Λ Insert element and fasten the clamps.
ö When the air cleaner warning lamp is ON,
clean the primary element.
ö The primary element should be replaced if
180D7EMA08
the warning lamp is ON after installation of a
clean primary element, or if the exhaust
smoke is still black.
ö Replace the primary element after 10 times
cleanings.
(2) Safety element
ö The safety element should be replaced at
the time the primary element is replaced.
ö Always replace the safety element. Never
attempt to reuse the safety element by
cleaning the element.
21076MA11A

7-27
10) FUEL TANK
(1) Fill fuel fully when system the operation to Strainer & cap
minimize water condensation, and check it with
fuel gauge before starting the machine. Fuel tank

(2) Drain the water and sediment in the fuel tank by

opening the plug.
ö Be sure to LOCK the cap of fuel tank.
ö Remove the strainer of the fuel tank and
clean it if contaminated.
Stop the engine when refueling.
All lights and flames shall be kept at a safe
distance while refueling. Drain plug

250D7EMA09

11) REPLACEMENT OF FUEL FILTER

(1) Clean around the filter head, remove the filter
and clean the gasket surface.
ÂWrench size : 90~95mm(3.5~3.8in)
Oil
(2) Replace the O-ring.
(3) Apply engine oil on the gasket of filter when
mounting, and tighten 3/4 to 1 turn more after the Cartridge
gasket touches the filter head.
(4) Relieve the air after mounting.
ö Do not pre-fill an on-engine fuel filter with fuel.
The system must be primed after the fuel filter
is installed. Pre filling the fuel filter can result
in debris entering the fuel system and
damaging fuel system components.
ö Check for fuel leakage after the engine starts. 7577A6MI14

ö If air is in the fuel system, the engine will not

start. Start engine after bleeding the air
according to the method of bleeding air.

7-28
12) PREFILTER
ö Inspect or drain the collection bowl of water
daily and replace the element every
500hours.
(1) Drain water
Bowl
Η Open bowl drain valve to evacuate water. Drain valve
Θ Close drain valve. Open Close

2907A6MI20

(2) Replace element

Η Drain the unit of fuel. Follow "Drain water"
instructions above.
Fuel warmer
Θ Remove element, fuel warmer and bowl from Open
filter head. Element
ö The bowl is reusable, do not damage or Bowl
discard. Open
Ι Separate element from bowl. Clean bowl and
seal gland.
2507A6MA31

Κ Lubricate new bowl seal with clean fuel or

motor oil and place in bowl gland. Filter head
Λ Attach bowl to new element firmly by hand. Fuel warmer
Μ Lubricate new element seal and place in
element top gland.
Ν Attach the element, fuel warmer and bowl to the Close
Element
head.
Bowl
Close
2507A6MA30

7-29
13) BLEEDING THE FUEL SYSTEM
(1) Air in fuel
ö Do not vent the fuel system on a hot engine;
this can cause fuel to spill onto a hot exhaust
manifold, which can cause a fire.
Η The replacement of fuel supply lines, fuel filters,
fuel injection pump, high-pressure fuel lines,
and injectors will let air enter the fuel system.
Air in the system will make the engine hard to
start, run rough, misfire, produce low power,
and can cause excessive smoke and a fuel
knock.

Θ Follow the specified procedure to bleed the air

from the fuel system.

START

ON OFF

75776MI28

Ι Since the fuel transfer pump provides positive

pressure through the fuel filter and supply line
to the fuel injection pump, loose connections or
defective seals can show as a fuel leak, not as
an air leak.

75776MI29

Κ For faster air purge, small amounts of air can be

bled from the fuel injection pump by operating
the hand primer located on the fuel transfer
pump or by cranking the engine.

75776MI30

7-30
Λ A source that is often overlooked for air to enter
the fuel system is between the inlet of the
prefilter and the suction tube in the tank. Fuel
tanks that have the outlet fitting at the top have
a suction tube that extends to the bottom of the
tank. Cracks or pins holes in the weld that join
the tube to the fitting can let air enter the fuel
system.

75776MI31

Μ A stuck-open injector can also blow combustion

gas back into the pump and cause air to be
present in the overflow. If the engine seems to be
misfiring or running rough, break all the injector
supply lines loose at the pump end. Crank the
engine, and observe the lines. If combustion gas
seems to be blowing back through the line, the
injector is stuck open. Remove the injector.
ö Use two wrenches when loosening the lines 75776MI32
at the fuel pump; one to hold the delivery
valve and one to loosen the fuel line.
ÂTightening torque : 2.45kgfÂm(18lbfÂft)

(2) Venting the high pressure lines

Keep hands and body parts away from the
high-pressure fuel lines. Fuel coming from
the high-pressure fuel lines and under
extreme pressure and can cause serious START
injury by penetrating the skin.
ON
Η Check for air in the high-pressure lines by OFF
loosening the fittings at the head. Crank the
engine to allow entrapped air to bleed from the 75776MI33
line. Tighten the fittings.
ÂTorque : 3.9kgfÂm(28lbfÂft)

Do not bleed the fuel system on a hot

engine; this can cause fuel to spill onto a hot
exhaust manifold, which can cause a fire.
Θ Operate the engine, and vent one line at a time START
until the engine runs smoothly.
ON
OFF

75776MI33

7-31
14) LEAKAGE OF FUEL
Be careful and clean the fuel hose, injection FIRE !!!
pump, fuel filter and other connections as the
leakage from these part can cause fire.

180D7EMI16

15) HYDRAULIC OIL CHECK

Level gauge
(1) Lower the forks on the ground at a flat location

;;;
;
as in the illustration. Red line
Stop the engine and then leave for about 5
minutes.
(2) Check the oil level at the level gauge. The level
gauge is located on the left side of the hydraulic
oil tank.
(3) The sight gauge should indicate the middle
position(between red lines).
ö Add hydraulic oil, if necessary.
250D7EMI21

16) FILLING HYDRAULIC OIL

(1) Stop the engine to the position of level check. Air breather

(2) Check air breather filter and replace it if

necessary.
(3) Loosen cap and fill the oil to the specified level.
(4) Start engine after filling and operate the work
equipment several times. Air breather

(5) Check the oil level at the level check position

after engine stops.
Element

Bolt

250D7EMA18

7-32
17) CHANGE THE HYDRAULIC OIL
(1) Lower the forks on the ground and extend the tilt Air breather
cylinder to the maximum.
(2) Loosen the cap and relieve the pressure in the
tank.
(3) Prepare a suitable drain pan.
(4) To drain the oil loosen the drain plug.
(5) After draining oil, tighten the drain plug.
(6) Fill proper amount of recommended oil.
Drain plug
(7) Start engine and run continually. Release the air
by full stroke of control lever.
ö The oil must be free of bubbles. If bubbles Drain pan

are present in the oil, air is entering the

hydraulic system. Inspect the suction hoses
and hose clamps for leakage or damage. 250D7EMA19

18) CLEANING AND REPLACING RETURN

FILTER
Clean and replace the return filter in the following
manner.
(1) Remove the flange by loosening the mounting
Return filter
bolt.
(2) Remove return filter from the tank.
Suction
filter
(3) Replace the return filter element with new one.
(4) Install the cover on the tank.
ÂTightening torque : 6.9Ü1.4kgfÂm
(50Ü10lbfÂft)

Drain plug

250D7EMA20

7-33
19) REPLACEMENT OF ELEMENT IN HYDRAULIC
TANK BREATHER Air breather

(1) Loosen the cap and relieve the pressure in the

tank.
(2) Loosen the screw and remove the cover.
(3) Pull out the filter.
(4) Replace the filter with new one. Air breather

(5) Reassemble by reverse order of disassembly.

ÂTightening torque of the bolts :
2.7~4.1kgfÂm (19.5~29.7lbfÂft) Element

Bolt

250D7EMA18

20) REPLACE THE ELEMENT OF THE PRESSURE

FILTER
(1) Remove the filter case from the filter assy.
(2) Pull out the filter element and clean filter case. OUT
IN

(3) Replace filter element and O-ring with new parts.

(4) Reassemble line filter.
Pressure filter Rear-frame

180D7EMA23

21) LUBRICATE RCV LEVER

Bellows
Remove bellows and grease the joint(A) and the
sliding parts(B).
B

160D7MI25

7-34
22) TIRE PRESSURE
(1) Inappropriate tire pressure is a primary cause for
tire damage. Insufficient tire pressure will
damage internal carcass of tire. Repeated
excessive bending will damage or break the
carcass. Excessive pressure will also cause
premature damage of tire.
(2) Recommended tire pressure(When tire is
cooled)

Size Pressure
Normal
14.00-24, 28PR 10.9kgf/cm2(156psi)

(3) Continuous operation will produce heat and

increase pressure on tire. But such phenomenon
was already taken into account when designing a
tire. Do not try to remove normally increased air
because tires may be crushed or overinflated.
(4) The three major causes for excessive heat and
pressure of tire are insufficient pressure,
Too low pressure
excessive load and overspeed. Avoid excessive
load and overspeed in order to keep tires in good
shape.
Do not inflate tires using flammable gases or
alcohol injector.
This cause explosion or personal injury.
Inflate tires at the pressure level recommended
by the manufacturer, and check periodically
pressure and wear of tires.
When replacing the inflated tire, do not stand Excess pressure
near the tire.
ö Check the tire when the tire is at normal
temperature and the machine is not loaded.
73036MI10

7-35
 Do not use recycled wheel parts.
When removing lockering or inflating tire, use
safety cable or chain to ensure safety.
Be sure to bleed air before removing
lockering. Never inflate tires unless the
lockering is assembled in its place.
ö Avoid the followings when traveling.
Η Rubbing tires against road bank or rack at
cargo-unloading spot.
Θ Tires slippage during working.
Ι Abrupt starting of machine.
Κ When oil, grease or gasoline smeared on tire,
clean those. Otherwise it may cause of
permanent deformation.

23) REPLACEMENT OF TIRE

Disassembly, reassembly, replacement and
repair of tire requires special skills and
equipment. Contact a tire repair shop.
(1) Tires to be replaced
Η Tires with broken or bent bead wires Tread
Θ Tires exposed more than 1/4 of carcass fly.
Ι Tires whose carcass is damaged more than 1/3
of the tire width.
Side wall Carcass
Κ Tires which show fly separation.
Λ Tires which has a radial crack near the
carcass.
Bead
Μ Tires which are judged to be unsuitable for use Valve
160D7MI35
because of deformation or damage.

(2) Separation of tire

Η After moving the machine to flat ground, lower
the fork to the ground and turn the parking
brake switch ON.

RELEASE
ON

250D7EMI36

7-36
 Θ Loosen slightly all wheel mounting.
ÂTools : Socket 22mm
Torque wrench
Extension bar
Ι Lift the machine with a jack.
Κ Loosen all wheel mounting nuts and replace the
tire.

Torque wrench
160D7MI37

(3) Direction of tire to be installed

Η Be careful that the valve should be facing the
outside.
Valve

160D7MI38

(4) Mounting of tire

Η Lightly tighten nuts as shown in the illustration.
Θ Lower the jack after tire is replaced. 10 1

Ι Tighten nuts according to the specified tighten 8 3

torque.
6 5
ÂFront : 34~38kgfÂm
ÂRear : 75~96kgfÂm 4 7

2 9

160D7MI39

24) STORING TIRES AFTER REMOVAL

As a basic rule, store the tires in a warehouse
which unauthorized persons cannot enter. If the
tire are stored outside, always erect a fence
around the tires and put up "No Entry" and other
warning signs that even young children can
understand.
Stand the tire on level ground, and block it Block
securely so that it cannot roll or fall over.
If the tire should fall over, get out of the way
quickly. The tires for construction equipment are 60 - 70ä
extremely heavy, so trying to hold the tire may lead
to serious injury. 73036MI20

7-37
25) CHECK TRANSMISSION OIL LEVEL
(1) The oil level check must be carried out as follows;
oil level check (weekly).
(2) At horizontally standing machine.
(3) Transmission in neutral position.
(4) In cold start phase, the engine must be running
about 2~3minutes at idling speed, and the
marking on the oil level gauge must then be lying
above the cold start mark COLD.
(5) At operating temperature of the transmission
(about 80~90Á C).
(6) At engine idling speed.
Level
(7) Loosen oil level gauge by counterclockwise gauge
rotation, remove and clean it.
(8) Insert oil level gauge slowly into the oil level tube
until contact is obtained, and pull it out again.
(9) On the oil level gauge, the oil level must be lying
in the zone HOT.
(10) Insert the oil level gauge again, and tighten it by HOT COLD

clockwise rotation. ZONE " HOT"

W hen checking, press the parking brake

switch and fix the tires with blocks. 250D7EMA41

26) REPLACEMENT OF TRANSMISSION OIL

AND FILTER ELEMENT
(1) Operate the machine for a few minutes in order Air breather
to warm the transmission oil.
(2) Move the machine to flat ground. Lower the
forks to the ground and slightly apply
downward force.
(3) Press the parking brake switch and stop the
engine.
(4) Open transmission air breather to relieve internal
air pressure.
Drain plug
(5) Remove the transmission drain plug. Allow the
transmission oil to drain into a suitable container. 180D7EMA42

7-38
 (6) Remove the transmission oil filter cartridge.
Dispose of the used transmission oil filter
cartridge properly.
(7) Clean the filter cartridge mounting base.
Remove any part of the filter cartridge gasket
that remains on the filter cartridge mounting
base. Transmission oil filter

(8) Apply a light coat of oil to the gasket of a new

transmission oil filter cartridge.
(9) Install the new transmission oil filter cartridge.
Screw the filter in until contacts with the sealing
surface is obtained and tighten it now by hand
about 1/3 to 1/2 turn.

(10) Mount the drain plug of transmission after

cleaning it.
(11) Fill the oil through level gauge inlet and check if
the oil is at the appropriate level.
(12) The proper oil amount is 32 liters (7.1 U.S. gallons)
As the machine is hot after operation wait
until the temperature has dropped.
I t is imperative to pay attention to absolute
cleanliness of oil and filter.
Binding is in any case the marking on the oil Level
gauge
level gauge.

HOT COLD

ZONE " HOT"

7-39
27) CLEANING TRANSMISSION AIR BREATHER
Air breather
(1) Remove dust or debris around the air breather.
(2) Remove the air breather and wash it with
cleaning oil.

180D7EMA45

28) CHECK AND SUPPLYING AXLE OIL

(1) Move the machine to flat ground. Air breather

(2) Open the axle air breather to relieve internal air

pressure.

250D7MI46

(3) Remove the plug and check the oil amount.

If the oil level is at the hole of the plug, it is Differential gear
normal.
Fill & oil
level plug

250D7MI47

7-40
(4) If the oil level is below the plug hole, supply oil Planetary gear
through a plug hole.
When checking the oil level, press the
parking brake switch and fix front and rear Plug
frames using the safety lock bar. HORIZ
OIL FILL
LEVEL

As the machine is hot after operation, wait

DRAIN
until the temperature has dropped.
ö Set the plug of planetary gear in parallel to
the ground. 250D7MI48

29 CHANGE THE AXLE OIL

(1) Place a case under drain plug to catch oil. Air breather
Fill & oil
(2) Remove the air breather to relieve internal level plug
pressure.
(3) Drain oil in the differential gear.
Η Remove the refilling plug and remove the drain
plug to drain oil off.
Θ Wash drain plug and install it. Drain plug

250D7MI49

(4) Drain oil in the planetary gear.

Η Drain oil by removing drain plug. Planetary gear
ö The drain plug should be facing the
ground.
OIL FILL
HORIZ
LEVEL

DRAIN

250D7MI50

(5) After draining, put the drain plug of planetary

Planetary gear
gear in parallel to the ground.
DRAIN

LEVEL

OIL FILL
HORIZ

250D7MI51

7-41
(6) Supply oil into the differential gear and the Differential gear
planetary gear.
ÂOil amount : 27.5˶(7.3U.S. gal) (Differential Fill & oil
level plug
gear)+2Ý3.2˶(0.8U.S. gal) (Planetary gear)
(7) Supply oil until it overflows from the oil filler, then
install the plug.
As the machine is hot after operation, wait
until the temperature has dropped.
ö If a work requires frequent use of brake,
replace it earlier than normal change
interval. Planetary gear

DRAIN
LEVEL

OIL FILL
HORIZ

250D7MI52

30) CLEANING AXLE BREATHER

(1) Remove dust or debris around the breather.
Air breather
(2) Remove the breather and wash it with cleaning
oil.

250D7MI46

31) STRAINER FOR THE TRANSMISSION COOL-

ING LINE
(1) Remove suction filter element from the flange
N
IO

assy using spanner.

T
C
U
S
N
R
U
T
E
R

(2) Check and clean throughly inside of the suction Regulator

filter element by using compressed air. Suction filter
element
(3) Reassemble the element on the flange assy.
ö Replace new element if necessary. LH - Side frame
250D7EMI60

7-42
32) LUBRICATION
(1) Supply grease through the grease nipple, using
grease gun. 4
(2) After lubricating, clean off spilled grease.
Press the parking brake switch and fix front
3
and rear tires with blocks.
Set the mast and forks in a stable position 1
2
and turn the hydraulic safety lock valve into
the lock position.
(3) Lubrication points
5 3 6
Η Adjust cylinder : 2EA
1 Adjust cylinder(2EA)
Θ Forks : 2EA
2 Fork(2EA)
Ι Tilt cylinder : Left/Right, 2EA 3 Tilt cylinder(Left/Right, 2EA)
4 Lift chain(2EA)
Κ Lift chain : 2EA 5 Mast support(Left/Right, 2EA)
6 Steering axle(5EA)
Λ Mast support : Left/Right, 2EA
Μ Steering axle : 5EA 250D7EOP17

33) FORKS REPLACEMENT

Η Lower the fork carriage until the forks are
approximately 25mm(1in) from the floor. Pin
Θ Take out the spring pin and remove the pin weld
assy.
Ι Remove only one fork at a time.
ö On larger forks it may be necessary to use a block
of wood. Cylinder
Κ Reverse the above procedure to install load forks.

250D7MS07

7-43
34) MAINTENANCE OF WORK EQUIPMENT
D F
(1) Lubricate to each point of working device.
Lubricate the grease to grease nipple in
accordance with lubrication intervals.

No. Description Qty C

A Fork adjustment cylinder pin 2
B Fork shaft 1
A
C Tilt cylinder pin 2 B
D Load chain 2
E Mast support pin 2
F Chain sheave pin 2
ö Shorten lubricating interval when working in the
E C
water or dusty place. 250D7EMI53

(2) Check for wear and tear of work equipment pins

and bushings.
(3) Check for damage of forks and mast linkage
part.
ö Check daily and lubricate the fork positioner
hanger bar and bottom plate where the fork is
contacted, or the forks may vibrate
temporarily while positioning.
250D7EMI54

(4) Dust seals are mounted on the rotating part of

working device to extend the lubricating interval.
ö Mount the lip to be faced out side when
replace the dust seal.
ö If it is assembled in wrong direction, it will
cause fast wear of pin and bushing, and Outside
create noise and vibration during operation.
ö Make sure the seals are not damaged or
deformed. 73036MI26

35) WORK EQUIPMENT SUPPORT

When carrying out inspection and maintenance
with the forks raised, fit a stand under the forks
securely to prevent the work equipment from
coming down. In addition, set the work equipment
control levers to the Hold position and Lock with
the safety lock.

250D7EMI55

7-44
8. ELECTRICAL SYSTEM

1) WIRING, GAUGES
Check regularly and repair loose or malfunctioning
gauges when found.
Loose
Open

250D7MI56

2) Welding repair
Before start to welding, follow the below
procedure.
(1) Shout off the engine and remove the starting
switch.
(2) Disconnect ground cable from battery by master
switch.
(3) Before carrying out any electric welding on the Cluster
ECU
machine, the battery cables should be
disconnected and the connectors pulled out of
the electronic control units(ECU, TCU, cluster
etc).
(4) Connect the earth(ground) lead of the welding Master switch

equipment as close to the welding points as

possible.
ö Do not weld or flame cut on pipes or tubes
that contain flammable fluids. Clean them OFF
thoroughly with nonflammable solvent before TCU
Battery
welding or flame cutting on them.
Do not attempt to welding work before carry
out the above.
If not, it will caused serious damage at electric
system. 250D7EMI57

7-45
9. AIR CONDITIONER AND HEATER

1) CLEANING AND REPLACING FILTER

ö Always stop the engine before servicing. Recircular
plenum assy
(1) Open the door, loosen the wing bolt and remove
the recircular plenum assembly.

160D7EMI58

(2) Clean the recircular plenum using a pressurized

air(Below 2kgf/cm2, 28psi).
When using pressurized air, be sure to wear
safety glasses.
(3) Inspect the filter after cleaning. If it is damaged
or badly contaminated, use a new filter.

2
Pressurized air 2kgf/cm below
77076MI50

2) PRECAUTIONS FOR USING AIR CONDITIONER

(1) When using the air conditioner for a long time,
open the window once every one hour.
(2) Be careful not to overcool the cab.
(3) The cab is properly cooled if the operator feels
cool when entering there from outside(About 5ÁC
lower than the outside temperature).
(4) When cooling, change air occasionally.
3) CHECK DURING SEASON
Ask the service center for replenishment of
refrigerant or other maintenance service so that
the cooling performance is not damaged.
4) CHECK DURING OFF-SEASON
Operate the air conditioner 2 or 3 times a month
(Each for a few minutes) to avoid loss of oil film in
the compressor.
5) Refrigerant amount : 850 Ü 50 g

7-46
10. REPLACEMENT AND CHECK

1) WIRING, GAUGES
Check regularly and repair the loose or malfunc-
tioning gauges when found.

13036MI29

2) BATTERY
(1) Clean
① Wash the terminal with hot water if it is
contaminated, and apply grease to the termi-
nals after washing.
The battery gas can explode. Keep sparks and
flames away from the batteries.
Always wear protective glasses when working
with the batteries.
Do not stain clothes or skin with the electrolyte
as it is acid.
Be careful not to get the electrolyte in the eyes. 36070FW05

Wash with clean water and go to the doctor if it

enters the eyes.

(2) Recycle
Never discard a battery.
Always return used batteries to one of the
following locations.
·A battery supplier
·An authorized battery collection facility
·Recycling facility
(3) Removing and installing
① Remove the lead from the ground side
(Normally the (-) terminal side) of the battery. It Remove (-) lead first
is dangerous to let a tool, etc., touch the (+)
1
terminal and the body at the same time, since
this causes a spark.
② When remounting, connect the ground Pos(+) Neg(-)
2
connection last
Do not allow tools to touch the (+) terminal and
the body of the truck at the same time. This can
cause sparking and explosion.
When reinstalling the cables after replaced the
battery, pay close attention to maintaining the
250D7EOM65
same alignment state of the cables as it was
when supplied. Otherwise, the machine can be
exposed to the fire hazards.
7-47
 Prior to reinstall the cable, inspect in detail and Connect (-) lead last
confirm the condition of the cables and replace
2
it when the cables possess any kind of
abnormal damages such as cracking and wear
out of the cable sheath that make you feel Pos(+) Neg(-)
1
somedangerous to use it. Do consult an expert
about this matter when you are not able to
judge its condition. It is strongly recommended
to keep the surroundings of the battery cables
250D7EOM66
clean so that the machine can be freed from the
risk of firing by eliminating the flammable
contaminations such as oil, dust and etc. acting
as a fire developer. Dispose of the old battery in
locally approved manner.

1) AIR CLEANER ELEMENT

Clamp
(1) Removal
① Double element type
Remove the cover by pulling off the clamps and
loosen the wing nut to pull out the outer
element.
※ During periodic service, replace only the outer
element. Do not replace the inner element
unless damaged.
Pressurized air
2
3kgf/cm below
(2) Cleaning
① Cleaning with compressed air
Blow dry compressed air(Max 30psi) from inside
along pleats. Next blow air form outside along
pleats, then blow from inside again and check
180D7EMA08
element.
② Cleaning with cleaning agent
If there is grease or carbon on the element, use a
special element cleaner, following the instruction
given with the cleaner. Have a spare element
ready so that the truck can start working again
immediately.

(3) Installation
When installing the element, check that the cleaner housing and element cover are completely in
close contact then fasten the clamps for the cover.
When using compressed air, use safety glasses, face shield and other protective clothes. Never
point the air nozzle at anyone. Never clean or replace air cleaner while engine is running.

7-48
 OSHA approved eye protection rated for 200kPa(30psi) is required for air cleaning
operation.
Replace element if exhaust is black, or if lack of engine power is noted even after cleaning
or element. When cleaning the element or element housing, cover the air flow outlet port of
the housing with a clean cloth or tape to prevent dirt or dust from entering. Do not clean the
elements by bumping or tapping them.

4) ENGINE
(1) Engine oil change
Warm up engine oil then park the truck in
level place with forks lowered. Stop the
engine and apply parking brake.
Remove drain plug and drain engine oil.
Drain plug
Also replace the engine oil filter. Check
oil level using dipstick after changing
the engine oil. Dispose of old oil in 180D7EOM160

locally approved manner.

(2) Engine oil filter replacement

ÂRemove the filter using a filter wrench.
ÂClean the filter by removing dust and oil
from the filter base bottom.
ÂInstall the new filter after thinly coating
the packing surface with engine oil.
A fter replacing the engine oil filter
element, start the engine to check for Engine oil
filter
oil leakage from the filter mounting 180D7EOM161
surface. Check the engine oil level
using the dipstick. When adding
engine oil, do not let the oil overflow
from the filler port.

(3) Fuel filter replacement

Replace the fuel filler when the engine
is cool. Carry out this maintenance in a Head
place away from fire. Removing the
fuel filler will produce explosive fumes.
Wipe off any spilled fuel or oil Element
immediately from the truck or
Filter cartridge
surrounding area. assembly
Η Using a filter wrench, remove the
cartridge.
Θ Fit the new cartridge with fuels coat the
160D7OM163
surface of the packing lightly with engine
oil, then install.

7-49
5) TRANSMISSION OIL
Do not touch hot components or allow hot oil to
contact your skin.
(1) Transmission oil
Park the truck in a level place and lower the
forks. Then stop the engine and apply the
parking brake.
(2) Oil level check Air breather
Η Open inspection plate, and oil level can be
checked using dipstick.
Dipstick
Θ Add oil through oil filler plug if necessary.
Ι Always check oil level using dipstick after add
oil.
(3) Change
Η Remove drain plug.
Θ When changing oil, remove strainer and clean it
with flushing oil.
O SHA approved eye protection rated for
200kPa(30psi) is required for air cleaning
operation.
ÂBlow dry compressed air from the inside of
strainer to outside and install when
completely dry.
ÂDispose of old oil in locally approved manner. 250D7EOM27

6) DIFFERENTIAL CASE
(1) Differential oil
Park the truck in a level place. Set the mast
vertical, and raise the forks approx. 1m. Put Filler plug

blocks under the fork carriage.

Then stop the engine and apply the parking
brake.
(2) Oil level check
Remove level plug, and check that oil is filled up
to hole.
(3) Change Drain plug

Change oil after removing drain plug.

Add oil until it just begins to flow out of the oil
level.
250D7OM162
Dispose of old oil in locally approved manner.

7-50
7) HYDRAULIC TANK
(1) Hydraulic oil change
Park the truck in a level place and lower the
forks.
Then stop the engine and apply the parking
brake.
Change oil after removing drain plug on tank
bottom.

Drain plug

Drain pan

250D7EOM28

(2) Strainer Cleaning

OSHA-approved eye protection rated for 200kPa(30psi) is required for air cleaning operation.
Η When changing oil, remove strainer and clean it with flushing oil. Blow dry compressed air from
inside of strainer to outside and install when completely dry.
Θ Dispose of oil in locally approved manner.
Ι Bleed the air after checking the oil level as below;
ÂStart engine.
ÂCheck for mast overhead clearance.
ÂFully raise and lower mast and also fully tilt it forward and backward several times.
ÂRecheck oil level.

7-51
8) COOLING SYSTEM
(1) Radiator fins cleaning
Remove dust between radiator fins with compressed air. Steam or water may be used instead of
compressed air. Air pressure should be less than 207kPa(30psi). Nozzle of cleaning device
should be held about 5cm(2in) from radiator fins. Also, check rubber hose connected to radiator.
Replace if cracked or deteriorated. Check that hose clamps are tight.
Be sure to keep air or steam nozzle at right angles to radiator. Wear safety glasses and a
face shield when using compressed air.

(2) Radiator Cleaning

Η Close drain valves and add clean, soft water
(City water, etc.) through water filler. Add
radiator cleaner and run the engine at idling
speed for 15 minutes.
Radiator
Θ Stop engine and drain water from drain valves.
Ι Add clean water and run at idling speed(5 to 10
minutes). Then stop the engine and drain
water. Compressed
air gun 250D7OM164
Κ Close drain valves and fill radiator with clean
water.
W 50%
For low temperatures, add antifreeze.(See AN 5 AT
TI 0% ER
FR
EE

cold weather operation for details). When ZE

Anti freeze
not using antifreeze, add anticorrosive
compound. Park truck on level ground and
clean radiator.
Radiator
ö Dispose of old antifreeze mixture in locally
approved manner.
250D7OM165

8) TIRE REPLACEMENT
Η Park the truck in a safe and level place suitable for changing the tire. Then lower the forks, stop
the engine, and apply the parking brake.
The tires are under high inflation pressure, so failure to follow the correct procedures,
when changing or servicing tires and rims could cause the tire to explode, causing serious
injury or damage. The tires and rims should always be serviced or changed by trained
personal using the correct tools and procedures. For details of procedures, contact your
HYUNDAI dealer. Wear safety glasses and a face shield when using compressed air.
Θ Block the tire at the opposite corner from the tire to be replaced.
Ι Loosen the lug nuts slightly with a lug nut wrench.
Κ Jack up the truck to raise the tire from the ground, then remove the lug nuts and take off the tire.
ö Points to fit jack when jacking up
Front tires: Bottom of outer mast or bottom of frame.
Rear tires: Bottom of counterweight or bottom of rear axle.

7-52
 When jacking up the truck, always check
carefully that the jack does not come out of
position. When jacking up the truck, never
go under the truck.

250D7EEOM29

A. For front tire installation

Λ Replace the tires and assemble inner tire, spacer, outer tire, wedge, clamp, lug nut. (Opposit way
to disassembly)
Μ Tighten all the lug nuts as much as it touches wedge.
Ν Tighten the each lug nut with 90 degree of nut rotation starting from circumferential direction.
If only one lug nut is excessively tightened, there is play in wheel. Please confirm there is no
wheel play while tightening.
Ξ Lower the jack to lower the truck on the ground, then tighten the lug nuts to the specified
tightening torgue.
Ο Check and adjust the inflation pressure: For details, see page, 5-3 CHECK BEFORE STARTING
ENGINE
B. For rear tire installation
Π Replace the tire and tighten the lug nuts partially. The mounting faces of the wheel, lug nuts and
wheels must be free from any dirt or lubricant of any kind.
Ρ Tighten the lug nuts on opposite sides in turn,
and check that there is no play in the wheel.
΢ Lower the jack to lower the truck to the ground, then tighten the lug nuts to the specified
tightening torque(For details, see service data).
Σ Check and adjust the inflation pressure.
Tire inflation pressure : For details, see page, 5-3 CHECK BEFORE STARTING ENGINE.
Precautions for adjusting the inflation pressure when repairing a puncture.
ö The tires used on forklift trucks have a high inflation pressure, so any cracks or
deformation of the rim are extremely dangerous. When adjusting the inflation pressure, do
not raise the pressure above the correct level under any circumstances. If the pressure of
the compressor is not adjusted beforehand, the pressure inside the tire will rise to the
maximum air pressure of the compressor, and this may cause a serious accident.
Therefore, always be extremely careful when carrying out this work.

7-53
10) FUSES REPLACEMENT
Fuse box #1
No. Capacity Color Related electrical component
ILLUM.LAMP
START KEY
Η 10A Red Illumination lamp Η 10A

SPARE(15A)
ࢠ݊ FUSE
Θ 15A Blue Fuel warmer (pre) FUSE
F/WARMER(PRE) HOLDER
Ι 15A Blue Front work lamp TCU(B+)
Θ ઴߹ુવ 15A
10A
Κ 15A Blue Rear work lamp ඹࠤෂഉ

Λ 15A Blue Wiper motor / Horn FRONTLAMP

TURN HORN(B+)
ECU
Ι WORK LAMP 10A
15A 5A
10A ΢
Μ 15A Blue Head lamp ୢࢺୁડ݊ ଲ੨କ

SPARE(10A)
Ν 5A Tan Beacon lamp REAR NEUTRAL
OPSS(B+) MONITOR(B+)
Ξ 5A Tan Cluster Κ WORK LAMP 15A5A RELAY 5A Ρ
บࢺୁડ݊ ஂ෍ࠧߑଲ
Ο 5A Tan Brake lamp
WIPER MOTOR/
ECU(B+) TCU
CABIN TILT
Π 15A Blue TCU Λ HORN 15A 15A Π
૕ଲ൵ࡦഉ෻ ൖ੨କ
Ρ 5A Tan Neutral relay
΢ 10A Red ECU HEAD LAMP
ECU(B+) BRAKE LAMP
CLUSTER(B+)

SPARE(5A)
Μ 15A 5A Ο
Σ 10A Red Engine preheat ෤݁޽ඹ जߑଲ೥޽ඹ
Τ 5A Tan Back-up lamp/Buzzer BEACON LAMP
CD/MP3(B+) CLUSTER
ROOM LAMP
Ν 5A 5A Ξ
Υ 10A Red OPSS լֈ݊ ծ‫׆‬ൡ
 15A Red Cigar-Jack/Tilt alarm
 15A Blue DC converter Fuse box #2
 10A Tan FDCU
ENGPREHEAT
E/G PREHEAT
 15A Red MP3/handsfree Σ
10A

SPARE(15A)
ફ஼ુવ FUSE
FUSE
 15A Blue Fuel warmer (main) HOLDER
HOLDER
BACK-UP
BACK-UP
 5A Tan Monitor 5A
Τ ࢽડ޽ඹऀୠ
 20A Blue Aircon / heater
 15A Blue Seat heater OPSS PARKING
PARKING
Υ 10A 10A 
 10A Red Parking ૶ୢୀԮ஺ୋ౿ சఙ

SPARE(10A)
 10A Red Start key CIGAR JACK/
CIGAR-JACK SEAT HEATER
10A Red TCU (B+)  15A
TILT ALARM 10A 15A 
 ਏԧ୎൙ൈੵ‫ޱ‬ ਏൈ વট
 10A Red Turn lamp DC DC AIRCON
AIRCON/
 5A Tan OPSS (B+) 
CONVERTER
CONVERTER 15A HEATER
/HEATER 20A
15A 
%$ ಟ࣊ഉ ઩ઘ಺ํഉ
 15A Blue ECU (B+)
 15A Blue ECU (B+) FDCU
TILTFDCU
ALARM MONITOR
SPARE(5A)

 10A
5A 5A 
൬ ুܑ ୪ઘ‫׆‬ ࡦ‫ۍ‬ഉ
 5A Tan CD/MP3 (B+)
 5A Tan Room lamp (B+) MP3HANDSFREE
CD/MP3
F/WARMER
HANDS FREE
 $% රߑଲઘ 10A15A (MAIN) 15A
10A 
 5A Tan Cluster (B+) ිலඹࠤ ઴߹ુવ ࡔ଴ෂഉ

 15A Blue Cabin tilt

Fuse box #3
 5A Tan Monitor (B+)
 5A Tan Horn(B+) START KEY
ILLUM.LAMP
 10A
SPARE(15A)

ਏ‫ܛ‬೬ FUSE
FUSE
Η Turn the starting switch OFF. HOLDER
TCU(B
FUEL )
+
WARMER
Θ Open the cover of the fuse box, and replace 
ൖ੨କ
10A
15A

fuses inside (To open the cover of the fuse FRONT

TURN LAMP HORN(B
ECU +)
box, push the side of the cover lightly with a  WORK LAMP 15A
10A 5A
10A 
ࢺේ஺ਏ݊ լଣ‫׆‬
SPARE(10A)

finger, and pull the cover forward to remove it.) REAR NEUTRAL +)
MONITOR(B
OPSS(B+)
WORK LAMP
5A
 ૶ୢୀԮ஺ୋ౿ 15A
RELAY 5A 
When replacing the fuse, check the ࡦ‫ۍ‬ഉ
WIPER MOTOR/
relationship between the fuse and the ECU(B+)
HORN
CABIN
TCU TILT
 15A 15A 
electrical components it protects. Always ଲ੨କ ಑थ ൙൝

replace fuses with a fuse of the same ECU(B

HEAD )
+
LAMP CLUSTER(B
BRAKE LAMP)
+
SPARE(5A)

 15A 5A 
capacity. Always turn the starting switch ଲ੨କ ծ‫׆‬ൡ

OFF before replacing any fuse. CDMP3(B

BEACON )
LAMP
+
ROOM LAMP(B+)
CLUSTER

 5A
ਓٛ݊
5A
$% රߑଲઘ

7-54
11) LAMP BULBS REPLACEMENT
Lamp Spec(24V)
Head lamp(up) 75W
Head lamp(down) 70W
Turn signal lamp 25W
Clearance lamp 10W
Stop lamp 25W
Backup lamp 10W
License lamp (option) 10W 160D7EOM69

Beacon lamp (option) Strobe type

Rear work lamp 65W
After checking that the fuse is not blown and that there is no disconnection in the wiring
harness, replace the lamp bulb.

12) FUNCTIONAL TESTS

You will start the engine to complete the functional tests, so be sure that:
ÂThe Parking brake is applied.
ÂDirectional control is in NEUTRAL.
ÂForks are fully lowered to the floor or ground.
ÂAll controls are in neutral or other correct position.
ÂYou are familiar with the safety procedures given in section 5, S tarting and operating
procedures, in this manual.
As you test the following components, be sure they are properly mounted and working correctly.

(1) 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 truck is put into operation.
(2) Hour meter
Start the engine and let it warm up until it runs evenly and accelerates smoothly when you push
on the accelerator pedal. Check the hour meter for operation with the engine running. Write the
hour meter reading on the PM report form. Report any malfunction or damage.

(3) Indicator lights

Check that all lights are functioning and indicate normal truck operation as described in section 3,
Know your truck, in this manual.

7-55
(4) Service brakes and inching pedal
With the direction control in NEUTRAL and the engine running, push the service brake pedal fully
down and hold. The brakes should apply before the pedal reaches the floorplate. If the pedal
continues to creep downward, report the failure immediately. Do not operate the truck until the
brakes are repaired. Perform the same check with the inching pedal.(Additional braking/inching
checks will follow).
(5) Parking brake
Check the function of the parking brake. Release, then reapply. To check parking brake holding
capability, park the lift truck on a grade and apply the parking brake. The parking brake should
hold a lift truck with rated load on a 15% grade.
Do not operate a lift truck if the service or parking brakes are not operating properly.
(6) Lift mechanisms and controls
Pull back on the tilt control lever and hold until
the mast reaches the full back tilt position. Push
forward on the lever to return the mast to the
vertical position. Release the lever.
Be sure that there is adequate overhead
clearance before raising the mast.
Pull back on the lift control lever and raise the
fork carriage to full height. Watch the mast 250D7OM73

assembly as it rises. Release the lever.

If the maximum fork height is not reached, this
indicates there is an inadequate(low) oil level in
the hydraulic sump tank or severe binding within
the mast.
Push forward on the lift control lever. Watch the
mast as it lowers. When the forks reach the
floor, release the lever.
All movements of the mast, fork carriage, and lift
chains must be even and smooth, without
binding or jerking. Watch for chain wobble or
looseness; the chains should have equal tension
and move smoothly without noticeable wobble.
(7) Auxiliary controls(Option)
If your lift truck is equipped with an attachment,
test the control lever for correct function and
briefly operate the attachment.

7-56
 (8) Steering system
ö The steering system, steering axle, and steering linkage on your truck should be inspected
periodically for abnormal looseness and damage, leaking seals, etc.. Also, be alert for any
changes in steering action. Hard steering, excessive freeplay(Looseness), or unusual
sound when turning or maneuvering indicates a need for inspection or servicing.
Check the steering system by moving the steering handwheel in a full right turn and then in a full
left turn. Return the handwheel to the straight ahead position. The steering system components
should operate smoothly when the handwheel is turned. Never operate a truck that has a
steering system fault.
Fasten your seat belt before driving the truck.

(9) Direction control, braking and inching

ö Be sure that the travel area is clear in front of the truck.
Η Push firmly on the brake pedal. Release the parking brake. Move the directional control lever
from NEUTRAL to FORWARD.
Θ Remove your right foot from the service brake pedal and put it on the accelerator pedal. Push
down until the truck moves slowly forward. Remove your foot from the accelerator pedal and
push down on the service brake pedal to stop the truck. The brakes should apply smoothly and
equally.
ö Be sure the travel area is clear behind the truck.
Ι Put the directional control lever in the REVERSE travel position. Release the service brake and
push down on the accelerator pedal until the truck moves slowly in the reverse direction.
Remove your foot from the accelerator pedal and push down on the service brake pedal to stop
the truck. The brakes should apply smoothly and equally.
Κ Put the directional control in FORWARD. Press the inching pedal fully down and hold. Depress
the accelerator. The truck should not move. Now, with the accelerator still depressed, slowly
release the inching pedal until the truck Inches forward smoothly and slowly.
ö Report any problems.
ö 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 record of all maintenance and operating problems you find.
13) FLUIDS, FILTERS AND ENGINE ACCESSORIES
To check fluid levels and other components within the engine compartment, unlatch and open the
hood to access the engine compartment.
To avoid the possibility of personal injury, never work in the engine compartment with the
engine running, except when it is absolutely necessary to check or make adjustments.
Take extreme care to keep hands, tools, loose clothing, etc., away from fan and drive belts.
Also remove watches, bracelets, and rings.
(1) Engine accessories
Inspect the engine coolant hoses and fan belt(s). Look for leaking and obvious damage, worn
(frayed) condition, breaks, etc. that could cause failure during operation.

7-57
(2) Engine air cleaner
Check the engine air cleaner for damage and contamination(excessive dirt build-up and clogging).
Be sure that the air cleaner hose is securely connected(not loose or leaking). Fan or cone shaped
dust deposit on tube or hose surfaces indicate a leak.
Change or service the air cleaner element every 500 operating hours, depending upon your
application. Service intervals may also be determined by the air restriction indicator.
(3) Battery
Inspect the battery for damage, cracks, leaking condition, etc.. If the terminals are corroded, clean
and protect them with HYUNDAI battery saver(Available from your HYUNDAI dealer). If your
battery has removable cell caps, check to be sure the cells are all filled. Refill them with distilled
water.
EXPLOSIVE GASES : Do not smoke or have open flames or sparks near batteries. An
explosion can cause injury or death.
(4) Engine cooling system
To check engine coolant level open the hood to
Max
the engine compartment. Visually inspect the
Normal HY
UN
DA
recovery bottle, locate the MAX and MIN marks. Min
I

The MAX mark indicates maximum level at FU

LOLL
W

operating temperature. The MIN mark indicates

additional coolant needs to be added to the 160D7OM61

system.
A level anywhere between the MAX and MIN marks is normal.
ö Inspect the coolant level in the overflow bottle only.
Do not remove the radiator cap when the radiator is hot. STEAM from the radiator will
cause severe burns. Do not remove the radiator cap to check the coolant level.
Never remove the radiator cap while the engine is running. Stop the engine and wait until it
has cooled. Failure to do so could result in serious personal injury from hot coolant or
steam blowout and/or damage to the cooling system or engine.
If the level is low, add a 50/50 mixture of specified coolant and water to the correct fill level. If you
have to add coolant more than once a month or if you have to add more than one quart at a time,
check the coolant system for leaks.
ÂCheck engine oil for presence of coolant leaking into engine.
ÂInspect the coolant for condition. Look for excessive contamination or rust or oil in the coolant
solution.
ÂCheck the PM time interval for need to change coolant.
ÂCheck the condition of radiator cap rubber seal and radiator filler neck for damage. Be sure they
are clean.
ÂCheck overflow hose for logging or damage.
ö Your lift truck cooling system is filled with a factory installed solution of 50% water and 50%
permanent-type antifreeze containing rust and corrosion inhibitors. You should leave the
solution in year around. Plain water may be used in an emergency, but replace it with the
specified coolant as soon as possible to avoid damage to the system. Do not use alcohol or
methanol antifreeze.

7-58
(5) Engine oil and filter
Locate the engine oil dipstick. Pull the dipstick out, wipe it with a clean wiper, and reinsert it fully
into the dipstick tube. Remove the dipstick and check oil level.
It is normal to add some oil between oil changes. Keep the oil level between the Full and Low mark on
the dipstick by adding oil as required. Do not overfill. Use the correct oil as specified under lubricant
specification.
It is recommended to:
ÂDrain and replace the engine crankcase oil initial 50 hours and every 500 operating hours(Depending
on application).
ÂRemove the oil pan drain plug to drain old oil after the truck has been in operation and the engine(oil)
is operating temperature.
Engine oil at operating temperature is hot and can cause burns. Beware of splashing oil.
ÂCarefully check for leaks after changing oil and installing new filter.
ö The time interval for changing engine oil depends upon your application and operating
conditions. To determine the correct schedule for your truck, it is suggested that you
periodically submit engine oil samples to a commercial laboratory for analysis of the
condition of the oil.
OIL PERFORMANCE DESIGNATION: To help achieve proper engine performance and durability, use
only engine lubricating oils of the proper quality. For diesel engines, HYUNDAI recommends that you
use motor oil that meets API service classification API CH-4 or better (SAE 15W-40) for diesel engines.
(6) Hydraulic sump tank
Check the hydraulic sump tank fluid level. Correct fluid level is important for proper system operation.
Low fluid level can cause pump damage. Over filling can cause loss of fluid or lift system malfunction.
Hydraulic fluid expands as its temperature rises. Therefore, it is preferable to check the fluid level at
operating temperature(after approximately 30 minutes of truck operation). To check the fluid level, first
park the truck on a level surface and apply the parking brake.
Put the mast in a vertical position and lower the fork carriage fully down. Pull the dipstick out, (attached
to the sump breather) wipe it with a clean wiper, and reinsert it. Remove dipstick and check oil level.
Keep the oil level above the LOW mark on the dipstick by adding recommended hydraulic fluid only, as
required. Do not overfill.
Check the condition of the hydraulic fluid(age, color or clarity, contamination). Change (replace) the oil
as necessary.
(7) Hydraulic fluid and filter change
Drain and replace the hydraulic sump fluid every 1000 operating hours.(Severe service or adverse
conditions may require more frequent fluid change). Replace the hydraulic oil filter element at every oil
change. Remove, clean, and reinstall the hydraulic and steer system suction line screens at first PM
and every 500 hours thereafter. Check for leaks after installation of the filter. Also, check that the
hydraulic line connections at the filter adapter are tightened correctly. The procedure for draining
hydraulic sump tank is in your service manual.
(8) Sump tank breather maintenance and inspection
Remove the sump tank fill cap/breather and inspect for excessive(obvious) contamination and damage.
Replace the fill cap/breather, per recommended PM schedule or as required by operating conditions.

7-59
 (9) Transmission fluid check
To check the transmission fluid locate the dipstick. The dipstick is located on the driver's right hand side
under the floor plate near the output flange of the transmission. Before checking, run the engine until
the unit is at operating temperature. This is important since transmission oil temperature should be
minimum of 65ÁC (149ÁF) to 100ÁC (212ÁF) maximum in continuous operation and a short-time
increase up to maximum 120ÁC (248ÁF) is permitted. The temperature is measured on the measuring
point under valve block of the transmission. The engine should also be at operating temperature. Apply
the parking brake.
With the engine operating at idle and the transmission in NEUTRAL, and the parking brake set, check
the fluid on the dipstick. Fill, if necessary, to the FULL mark on the dipstick, using the transmission fluid
recommended by HYUNDAI.
ö Check the planned maintenance interval (operating hours) or the condition of the oil to
determine if the transmission fluid needs to be changed.
14) LUBRICATION
(1) Truck chassis inspection and lubrication
Lubrication and inspection of truck chassis components, including steering wheels, steering axle
linkage, steering cylinder, and wheel bearings are easier if the truck is raised and blocked up
under the frame. Refer to your service manual for additional information on truck blocking and
jacking. Also refer to your service manual for the location of grease fittings.
Inspect the steering cylinder piston rods, seals, and fasteners for damage, leaks, and looseness.
Lubricate the steering axle linkage rod ends and linkage pivot points. Be sure to clean the grease
fittings before lubricating, and remove the excess grease from all points after lubricating.
Lubricate miscellaneous linkage as needed.
(2) Mast and tilt cylinder lubrication
Clean the fittings and lubricate the tilt cylinder rod end bushings(forward end) and both the base
rod-end bushings(rear end). Clean and lubricate the mast trunnion bushings.
(3) Lift chains
Lubricate the entire length of the mast rail lift and carriage chains with HYUNDAI chain and cable
lube.
14) AIR CLEANING
Always maintain a lift truck in a clean condition. Do not allow dirt, dust, lint, or other contaminants
to accumulate on the truck. Keep the truck free from leaking oil and grease. Wipe up all oil spills.
Keep the controls and floorboards clean, dry, and safe. A clean truck makes it easier to see
leakage and loose, missing, or damaged parts, and helps prevent fires. A clean truck runs cooler.
The environment in which a lift truck operates determines how often and to what extent cleaning is
necessary.
For example, trucks operating in manufacturing plants that have a high level of dirt, dust, or lint(for
example, cotton fibers or paper dust) in the air or on the floor or ground, require more frequent
cleaning. The radiator especially may require daily air cleaning to ensure correct cooling.
If air pressure does not remove heavy deposits of grease, oil, etc., it may be necessary to use
steam or liquid spray cleaner.
ö Lift trucks should be air cleaned at every PM interval, or more often if necessary.
Use an air hose with special adapter or extension, a control valve, and a nozzle to direct the air
properly. Use clean, dry, low pressure, compressed air. Restrict air pressure to 207kPa (30psi),
maximum(OSHA requirement).
7-60
 Wear suitable eye protection and protective clothing when air cleaning. Never point the air
nozzle at anyone.
Air clean the mast assembly, drive axle, radiator- from both counterweight and engine side, engine
and accessories, drive line and related components, and steering axle and cylinder.
15) CRITICAL FASTENER TORQUE CHECKS
Fasteners in highly loaded(critical) components can quickly fail if they become loosened. Also,
loose fasteners can cause damage or failure of the component. For safety, it is important that the
correct torque be maintained on all critical fasteners of components that directly support, handle, or
control the load and protect the operator. (SEE SECTION 8. SPECIFICATIONS)
Critical items include:
ÂDrive axle mounting
ÂCabin
ÂDrive and steering wheel mounting
ÂTilt cylinder mounting and yokes
ÂCounterweight mounting
ÂMast mounting and components
Torque specifications are in your service manual.
16) LIFT CHAIN MAINTENANCE
The chain system on the mast was designed for safe, efficient, and reliable transmission of lifting
force from hydraulic cylinder to the forks. Safe use of your truck with minimum down time depends
on the correct care and maintenance of the lift chains. Most complaints of unacceptable chain
performance are a result of poor maintenance. Chains need periodic maintenance to give
maximum service life.
Do not attempt to repair a worn chain. Replace worn or damaged chains with a set (LH & RH).
Do not piece chains together.
(1) Lift chain inspection and measurement
Inspect and lubricate the lift chains every 10 hours or daily and check tension every 250 hours or
monthly. When operating in corrosive environments, inspect the chains every 50 hours. During
the inspection, check for the following conditions:
ÂRust and corrosion, cracked plates, raised or turned pins, tight joints, wear, and worn pins or
holes.
ÂWhen the pins or holes become worn, the chain becomes longer. When a section of chain is
3% longer than a section of new chain, the chain is worn and must be discarded.
ÂChain wear can be measured by using a chain scale or a steel tape measure. When checking
chain wear, be sure to measure a segment of chain that moves over a sheave. Do not repair
chains by cutting out the worn section and joining in a new piece. If part of a chain is worn,
replace all the chains of both sides on a truck.
(2) Lift chain lubrication
Lift chain lubrication is an important part of your maintenance program. The lift chains operate
under heavy loadings and function more safely and have longer life if they are regularly and
correctly lubricated. HYUNDAI chain lubricant is recommended; it is easily sprayed on and
provides superior lubrication. Heavy motor oil may also be used as a lubricant and corrosion
inhibitor.

7-61
(3) Lift chain wear and replacement criteria
Η New chain length
The distance from the first pin counted to the
last pin counted in a span while the chains are
lifting a small load.
Θ Worn chain length 2
1 3
The distance from the first pin counted to the
last pin counted in a span while the chains are
lifting a small load.
Ι Span 4
The number of pins in the length(Segment) of
(EA)
chain to be measured.
Κ Pitch D255OM15

The distance from the center of one pin to the

center of the next pin.
All chains must be replaced if any link has wear of 3% or more, or if any of the damaged conditions
notes above are found during inspection. Order replacement chains from your HYUNDAI dealer.
Replace all chains as a set. Do not remove factory lubrication or paint new chains. Replace anchor
pins and worn or broken anchors when installing new chains. Adjust tension on new chains.
Lubricate chains when they are installed on the mast.
ö Please refer to your service manual for additional information on lift chain measurement
and maintenance.

7-62
11. HANDLING TRUCK IN EXTREMELY HOT PLACES

Pay careful attention particularly to the following

points when handling the truck in extremely hot
places.
1) Scale and rust form more easily in the cooling
system, so wash with anticorrosion liquid. Always Radiator
try to have clean and soft water circulating in the
system.
2) Clogging of the radiator fins is one cause of Compressed
air gun 250D7OM164
overheating, so use air or water jets to clean the
fins. When doing this, the air nozzle must be at
right angles to the radiator.
ÂAir pressure max : 2kgfcm2(30psi)
3) Check the fan belt tension. If it is too slack, adjust the tension. (SEE SECTION 8. SPECIFICATIONS)
4) In case of overheating, do not stop the engine immediately.
(1) Run the engine at low idling.
(2) Open the hood to ventilate the engine compartment.
(3) When the water temperature drops, stop the engine.
(4) 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 radiator
cap while the engine is hot. Steam may spurt out. Wait until the water temperature drops. It
is extremely dangerous to try to check the fan belt tension while the engine is running. When
inspecting the fan belt or other moving parts, or near such parts, always stop the engine first.

7-63
12. COLD WEATHER OPERATION

1) PREPARATION FOR LOW TEMPERATURE

(1) Replace lubrication oil with oil of the prescribed Min ambient
viscosity. temperature -5 -10 -15 -20 -25 -30
(Á
C)
(2) Fuel of low pour point must be used. ASTM
Amount of
D975 No.1 diesel fuel should be used at ambient antifreeze(%)
25 30 35 40 45 50
temperature lower than -5ÁC.
Amount of
(3) When ambient temperatures are below use an 75 70 65 60 55 50
water(%)
anti-freeze mixture per the above table to
prevent freezing of the cooling system.
Use permanent type antifreeze.
Use soft water(city water, etc.) as mixing water.
Cooling system must be thoroughly flushed before filling with antifreeze mixture.
When the climate becomes warmer and antifreeze is not needed, replace with soft water
(city water, etc.) after thoroughly cleaning the cooling system.
Do not expose antifreeze to flame. It is inflammable.
ö Dispose of old antifreeze mixture in locally approved manner.

2) BATTERY
As ambient temperature drops, battery capacity will drop and electrolyte may sometimes freeze if
battery charge is low. Maintain battery at a charge level of over 75% and insulate it against cold
temperature so that truck can be readily started the next morning.
ö When the electrolyte level is low, add distilled water in the morning before work instead of
after the day's work. This is to prevent fluid from freezing at night.
3) CARE AFTER DAILY OPERATION

(1) Drain water from fuel system to prevent freezing.

(2) Fill the tank at the end of each day of operation to drive out moisture laden air to prevent
condensation.
Do not fill the tank to top.
Explosive fumes may be present during refueling.

7-64
13. RECOMMENDATION TABLE FOR LUBRICANTS

1) NEW TRUCK
New truck uses following fuel, coolant and lubricant.
Description Specification

Engine oil SAE 10W-30/15W-40(API CH4 class or better)

T/M oil Engine oil SAE10W-30(API CF4 class or better)
Axle oil/Brake cooling oil SAE 80W-90/Donax TD
Hydraulic oil ISO VG32/VG46/VG68, Hyundai genuine long life hydraulic oil
Grease Lithium base grease NLGI No.2
Fuel ASTM D975-No.2
Coolant (DCA4) ASTM D6210
Mixture of 50% ethylene glycol base antifreeze and 50% water
Mixture of 60% ethylene glycol base antifreeze and 40% water
ㆍSAE : Society of Automotive Engineers
ㆍAPI : American petroleum Institute
ㆍISO : International Organization for Standardization
ㆍNLGI : National Lubricating Grease Institute
ㆍASTM : American Society of Testing and Material

7-65
 14. FUEL AND LUBRICANTS

Ambient temperature
ÁC
ÁF

Service Kind of Capacity˶(U.S.gal)

-20 -10 0 10 20 30 40
(-4) (14) (32) (50) (68) (86) (104)

SAE 30

Engine oil SAE 10W

Engine oil 20
pan (5.3)
SAE 10W-30

SAE 15W-40

Torque SAE 10W-30

converter Engine oil 27
transmission (7.1)
SAE 15W-40

27.5+2Ý3.2
Gear oil SAE 80W-90/API GL-5
(7.3+2Ý0.8)
Axle
brake
33
Cooling oil (8.7) DONAX TD

Hydraulic Hydraulic 268 ISO VG32

tank oil (71)
ISO VG46
Cabin tilt Hydraulic
0.7 (0.2) ISO VG68
hand pump oil

ASTM D975 No.1

531
Fuel tank Diesel fuel
(139.7)
ASTM D975 No.2

NLGI No.1
Fitting -
(Grease nipple) Grease
NLGI No.2

Antifreeze:Water
Radiator 30.6 (8.08) Ethylene glycol base permanent type
50:50

NOTES :
Η SAE numbers given to engine oil should be selected according to ambient temperature.
Θ
For engine oil used in engine oil pan, use SAE 10W oil when the temperature at the time of
engine start up is below 0ÁC , even if the ambient temperature in daytime is expected to rise to
10ÁC or more.
Ι

If any engine oil of API service class CF is used instead of class CH4 engine oil, the frequency
of oil change must be doubled.

7-66
 8. SPECIFICATIONS
1. SPECIFICATION TABLE

Model Unit 250D-7E

Capacity kg 25000
Load center R mm 1200
Weight(Unloaded) kg 37020
Lifting height H mm 4030
Free lift B mm 0
Fork Lifting speed (Unload/Load) mm/sec 280/250
Lowering speed (Unload/Load) mm/sec 300/400
LÝWÝT L,W,T mm 2450Ý250Ý110
Tilt angle (forward/backward) C/C degree 12/10
Mast Max height K mm 5837
Min height M mm 3877
Travel speed (Unload/Load) km/h 31.7/28.3
Body Gradeability (Load) degree 15.7 (28.2%)
Min turning radius (Outside) E mm 5800
Max hydraulic pressure kgf/cm2 210
ETC Hydraulic oil tank ˶ 268
Fuel tank ˶ 531
Overall length A mm 6362
Overall width C mm 3050
Cabin height B mm 3223
Ground clearance (Mast) D mm 300
Wheel base F mm 4250
Wheel tread front/rear G/G' mm 2212/2140

8-1
2. SPECIFICATION FOR MAJOR COMPONENTS

1) ENGINE

Item Unit Specification

Model  CUMMINS QSC

Type  4 cycle turbocharged and inter cooled engine
Cooling Method  Water cooling
Number of cylinders and arrangement  6 cylinders, In-line
Firing order  1-5-3-6-2-4
Combustion chamber type  Direct injection
Cylinder bore X stroke mm(in) 114Ý135mm (4.49"Ý5.31")
Piston displacement cc(cu in) 8300 (510)
Compression ratio  17.5 : 1
Rated gross horse power ps/rpm 264/2200
Maximum gross torque at rpm kgfÂm/rpm 120.4/1400
Engine oil quantity ˶(U.S.gal) 20 (5.3)
Dry weight kg(lb) 723 (1594)
High idling speed rpm 2350
Low idling speed rpm 750
Rated fuel consumption g/ps.hr 165
Starting motor V-kW DENSO, 24-7.5
Alternator V-A 24-70
Battery V-AH 24-100

2) MAIN PUMP

Item Unit Specification

Type  Axial piston variable pump

Capacity cc/rev 7474
Maximum operating pressure bar 300
Rated speed (Max/Min) rpm 2550/500

3) MAIN CONTROL VALVE

Item Unit Specification

Type  Sectional
Operating method  Hydraulic pilot
Main relief valve pressure bar 210/165
Flow capacity lpm 400

8-2
 (4) STEERING UNIT

Item Unit Specification

Type  Load sensing/Non load reaction/Dynamic signal

Capacity cc/rev 630
Rated flow lpm 52

(5) POWER TRAIN DEVICES

Item Specification

Model W340, 1.773/271 (ZF SACH)

Torque converter Type 3 Element, 1 stage, 2 phase
Stall ratio 1.773 : 1
Type Full auto, power shift
Gear shift(FR/RR) 3/3
Transmission Adjustment Electrical single lever type
FR 1 : 5.683 2 : 2.304 3 : 0.963
Overhaul ratio
RR 1 : 5.041 2 : 2.044 3 : 0.854
Type Front-wheel drive type, fixed location
Axle Gear ratio 17.52 : 1
Gear Ring & Pinion gear type
Q'ty(FR/RR) Double : 4/2
Wheels Front(drive) 14.00-24-28 PR
Rear(steer) 14.00-24-28 PR
Travel Front wheel, wet disc brake
Brakes
Parking Front wheel, hydraulic released brake
Type Full hydraulic, power steering
Steering
Steering angle 71.9äto both right and left angle, respectively

8-3
3. TIGHTENING TORQUE

No Items Size kgf m lbf ft

1 Engine mounting bolt, nut M24 3.0 100 15 723 109

Engine
2 Radiator mounting bolt, nut M12 1.75 12.8 3.0 93 22
3 Hydraulic pump mounting bolt M12 1.75 12.8 3.0 93 22
Hydraulic
4 system MCV mounting bolt, nut M16 2.0 29.7 4.5 215 32
5 Steering unit mounting bolt M10 1.5 6.9 1.4 50 10
6 Transmission mounting bolt, nut M20 2.5 57.9 8.7 419 63
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
Power
9 Steering axle mounting bolt, nut M48 5.0 199 30 1440 217
train
10 system Front wheel mounting nut M18 2.0 35 2 253 14.5
Rear wheel mounting nut M22 1.5 84 12 608 87
11 Propeller shaft(To T/M) M12 1.5 15 2 109 14.5
Propeller shaft(To D/Axle) M12 1.75 12.3 2.5 89 18
Counterweight mounting bolt 1 M30 3.5 199 29.9 1439 216
12
Counterweight mounting bolt 2 M24 3.0 100 15 723 109
13 Others Operator's seat mounting nut M 8 1.25 3.4 0.7 24.6 5
14 Cab mounting nut M16 2.0 29.7 4.5 215 32
15 Mast mounting bolt M14 2.0 19.6 2.9 144 23

8-4
 9 . TROUBLESHOOTING
1. ENGINE SYSTEM

Trouble symptom Probable cause Remedy

Oil pressure caution lamp fails ÂLow oil level in oil pan. ÂAdd oil.
to go out. ÂOil filter element clogged. ÂReplace element.
ÂLoose or worn oil pipe joint leaks oil. ÂCheck and repair.
Radiator pressure valve spouts ÂLack of cooling water or water lea- ÂAdd water or repair.
steam. kage.
ÂLoosen fan belt. ÂAdjust belt.
ÂDust and scale accumulated in, cool- ÂChange water and clean the interior
ing system. of cooling system.
Water temp gauge indicates ÂRadiator fin clogged or fin damaged. ÂClean or repair.
red range, on right. ÂThermostat or water temp gauge fau- ÂReplace
lty.
ÂRadiator filler cap loosening. ÂRetighten cap or replace packing.
Water temp gauge indicates ÂThermostat faulty. ÂReplace
red range, on left. ÂWater temperature gauge faulty. ÂReplace
Engine fails to start. ÂLack of fuel. ÂAddfuel.
ÂAir mixed in fuel system. ÂRepair.
ÂFuel injection pump or nozzle defec- ÂReplace.
tive.
ÂStarting motor rotates slowly. ÂSee " Electrical system."
ÂEngine compression insufficient.
ÂValve clearance out of adjustment. ÂAdjust clearance
Engine emits whitish or bluish ÂExcessive quantity of oil in oil pan. ÂReduce oil quantity.
smoke. ÂPoor quality of fuel. ÂReplace with specified fuel.
Abnormal sound heard. ÂPoor quality of fuel. ÂReplace with specified fuel.
(Fuel combustion or mechani- ÂOverheating ÂSee Symptom "Radiator pressure val-
cal sound) ve spouts steam".
ÂMuffler interior damaged. ÂReplace
ÂExcessively large valve clearance. ÂAdjust clearance.

9-1
2. ELECTRICAL SYSTEM

Trouble symptom Probable cause Remedy

Lamps dimming even at maxi- ÂFaulty wiring. ÂCheck for loose terminal and discon-
mum engine speed. nected wire.
Lamps flicker during engine ÂImproper belt tension. ÂAdjust belt tension.
operation.
Charge lamp does not light du ÂCharge lamp defective. ÂReplace.
-ring normal engine operation. ÂFaulty wiring. ÂCheck and repair.
Alternator makes abnormal ÂAlternator defective. ÂReplace
sounds.
Starting motor fails to run. ÂFaulty wiring. ÂCheck and repair.
ÂInsufficient battery voltage. ÂRecharge battery.
Starting motor pinion repeats ÂInsufficient battery voltage. ÂRecharge battery.
going in and out.
Excessively low starting motor ÂInsufficient battery voltage. ÂRecharge battery.
speed. ÂStarting motor defective. ÂReplace
Starting motor comes to a stop ÂFaulty wiring. ÂCheck and repair.
before engine starts up. ÂInsufficient battery voltage. ÂRecharge battery.
Heater signal does not beco- ÂFaulty wiring. ÂCheck and repair.
me red. ÂGlow plug damaged. ÂReplace
Engine oil pressure caution ÂCaution lamp defective. ÂReplace
lamp does not light when enig- ÂCaution lamp switch defective. ÂReplace
ne is stopped
(with starting switch left in"ON"
position).

9-2
3. TORQUE FLOW SYSTEM

Trouble symptom Probable cause Remedy

1. Excessive oil
temperature rise ÂImproper oil level. ÂCheck oil level. Add or drain oil as
1) Torque converter necessary.
ÂImpeller interfering with surroundings. ÂAfter draining oil from oil tank and tra-
nsmission, check and replace interfe-
ring parts.
ÂStator and free wheel malfunctioning. ÂCheck engine (stalling) speed.
If necessary, replace.
ÂAir sucked in. ÂCheck the inlet side joint or pipe.
If necessary, retighten joint or repla-
ce gasket.
ÂWater intruding into transmission ÂCheck drained oil.
case If necessary, change oil.
ÂBearing worn or seizing. ÂDisassemble, inspect, repair or repla-
ce.
ÂGauge malfunctioning. ÂCheck and, if necessary, replace.
2) Transmission ÂClutch dragging. ÂCheck to see whether or not machi-
ne moves even when transmission is
placed in neutral position. If so, repl-
ace clutch plate.
ÂBearing worn or seized. ÂDisassemble, check and replace.
2. Noise operation
1) Torque converter ÂCavitation produced. ÂChange oil, replace parts leaking air.
ÂFlexible plate damaged. ÂListen to rotating sound at lowspeed
operation. If necessary, replace flex-
ible plate.
ÂBearing damaged or worn. ÂDisassemble, check and replace.
ÂGear damaged. ÂDisassemble, check and replace.
ÂImpeller interfering with surroundings. ÂCheck impeller or check drained oil
for mixing of foreign matter.
If necessary, change oil.
ÂBolt loosening. ÂDisassemble and check. If necessa-
ry, retighten or replace.
ÂSpline worn. ÂDisassemble, check and replace.
ÂNoise gear pump operation. ÂDisassemble, check and replace.
2) Transmission ÂDragging caused by seizing clutch. ÂCheck to see whether or not truck
moves even when transmission is in
neutral position. If so, replace clutch
ÂBearing worn or seizing. plate.
ÂGear damaged. ÂDisassemble, check and replace
ÂBolt loosening. ÂDisassemble, check and replace
ÂDisassemble, check and retighten or
replace
ÂSpline worn. ÂDisassemble, check and replace

9-3
 Trouble symptom Probable cause Remedy
3.Low output power
1) Torque converter ÂInsufficient hydraulic pressure :

Low oil level. 
Check oil level and add oil
 Air sucked in. 
Check joints and pipes.
If necessary, retighten joint or repla-
ce packing.
 Oil filter clogging. 
Check and replace
 Oil pump worn. 
Check oil pressure. If necessary rep-
(Low delivery flow) lace pump.

Regulator valve coil spring fatigu- 
Check spring tension. If necessary,
ed. replace.
 Control valve spool malfunctioning. 
Disassemble, check and repair or re-
place.
 Piston or O-ring worn. 
Disassemble, check measure and re-
place.
ÂStator free wheel cam damaged. 
Check stalling speed.
(Increased engine load will cause ex-
cessive drop of stalling speed.)

Check oil temperature rise.
If any, replace free wheel.
2) Transmission ÂFlexile plate deformed ÂReplace flexible plate
ÂStator free wheel seizing. 
Check temperature plate.
(No-load will cause temperature rise)

Replace free wheel if a drop of start-
ing output is found.
ÂImpeller damaged for interfering with 
Check drained oil for foreign matter.
the surroundings. If any, change oil.
ÂUse of poor quality of oil or arising of 
Check and change oil.
air bubbles.
 Air sucked in from inlet side. 
Check joints and pipes.
If necessary, retighten joint or replace
packing.
 Low torque converter oil pressure 
Check oil pressure.
accelerates generation of air beb-
bles.
 Oil mixing with water. 
Check drained oil and change oil.
 Inching rod out of adjustment. 
Check and adjust.
ÂClutch slipping
 Lowering of weight. 
Check oil pressure.
 Piston ring or O-ring worn. 
Disassemble, check, measure and
replace.
 Clutch piston damaged. 
Disassemble, check and replace.
 Clutch plate seizing or dragging. 
Check to see whether or not truck
moves even when transmission is in
neutral position. If so, replace.

9-4
 Trouble symptom Probable cause Remedy
4.Unusual oil pressure
1) Oil pressure is high ÂControl valve malfunctioning. (1)Check for spool operation.
If necessary, replace valve.
(2)Check for clogging of small hole in
valve body. If necessary, clean or
repair.
ÂCold weather. (high oil viscosity) ÂWhen atmospheric temp is below fr-
eezing point
(when normal oil pressure is recover-
ed if heated to 60 ~ 80ÁC), change
oil.
ÂUse of improper oil. ÂCheck and change oil.
2) Oil pressure is low ÂGear pump malfunctioning(worn). ÂDisassemble, check and replace.
ÂOil leaks excessively :
(1)Control valve oil spring defective. ÂCheck spring tension (see spring sp-
ecification).
If necessary replace.
(2)Control valve spool defective. ÂDisassemble, check, and repair or re-
place valve.
ÂAir sucked in. ÂCheck joints and pipes. If necessary,
retighten joint or replace packing.
ÂLow oil level. ÂCheck oil level and add oil.
ÂOil filter clogging. ÂCheck and replace.
3) Transmission ÂOil leaks excessively. ÂDisassemble, check (piston ring and
O-ring for wear and other defects),
and replace.
5.Power is not transmitted
1) Torque converter ÂClutch plate damaged. ÂCheck for damage by listening to ab-
normal sounds at a low converter sp-
eed and replace.
ÂLow oil level. ÂCheck oil level and add oil
ÂOil pump driving system faulty. ÂDisassemble and check for wear of
pump gear, shaft and spline.
Replace defective parts.
ÂShaft broken. ÂCheck and replace.
ÂLack of oil pressure. ÂCheck oil pump gear for wear and for
oil suction force.
If necessary, replace pump.
2) Transmission ÂLow oil level. ÂCheck oil level and add oil.
ÂInching valve and link lever improper- ÂCheck measure and adjust.
ly positioned.
ÂForward/reverse spool and link lever ÂCheck and adjust.
improperly positioned.
ÂClutch fails to disengage :
(1)Clutch case piston ring defective. ÂDisassemble, check and replace
(2)Main shaft plug slipping out. ÂDisassemble, check and repair or re-
place
ÂClutch seizing. ÂCheck to see whether or not truck
moves even then transmission is in
neutral position. If so, replace.
ÂShaft broken off. ÂDisassemble, check(main shaft, etc.),
and replace.
ÂClutch drum damaged (spring groove). ÂDisassemble, check and replace.
ÂClutch snap ring broken. ÂDisassemble, check and repair or re-
place.

9-5
 Trouble symptom Probable cause Remedy
5. Power is not transmitted ÂForeign matter intruding into oil pass- ÂDisassemble, check and repair or
(Continue) age to clutch. replace.
ÂShaft spline worn. ÂDisassemble, check and replace.
6. Oil leakage ÂOil leaks from oil seal. ÂDisassemble and check for wear of
(Transmission and torque seal lips and mating sliding surfaces
converter) (pump boss, coupling etc.)
Replace oil seal, pump boss, coupl-
ing, etc.
ÂOil leaks from case joining surfaces. ÂCheck and retighten or replace pack-
ing.
ÂOil leaks from joint or pipe. ÂCheck and repair or replace gasket.
ÂOil leaks from drain plug. ÂCheck and retighten or gasket.
ÂOil leaks from a crack. ÂCheck and replace cracked part.

9-6
4. STEERING SYSTEM

Trouble symptom Probable cause Remedy

1. Steering wheel drags. ÂLow oil pressure. ÂCheck locknut. Repair.
ÂBearing faulty. ÂClean or replace.
ÂSpring spool faulty. ÂClean or replace.
ÂReaction plunger faulty. ÂReplace.
ÂBall-and-screw assembly faulty. ÂClean or replace.
ÂSector shaft adjusting screw excessi- ÂAdjust.
vely tight.
ÂGears poorly meshing. ÂCheck and correct meshing.
ÂFlow divider coil spring fatigued. ÂReplace.
2. Steering wheel fails to return ÂBearing faulty. ÂClean or replace.
smoothly. ÂReaction plunger faulty. ÂReplace.
ÂBall-and-screw assy faulty. ÂClean or replace.
ÂGears poorly meshing. ÂCheck and correct meshing.
3. Steering wheel turns unstea- ÂLocknut loosening. ÂRetighten.
dily. ÂMetal spring deteriorated. ÂReplace.
Steering system makes abn- ÂGear backlash out of adjustment. ÂAdjust.
ormal sound or vibration. ÂAir in oil circuit. ÂBleed air.
4. Abnormal sound heard Valve
when steering wheel ÂFaulty. (Valve fails to open.) ÂAdjust valve set pressure and check
is turned fully for specified oil pressure.
Piping
ÂPipe (from pump to power steering ÂRepair or replace.
cylinder) dented or clogged.
5. Piping makes abnormal Oil pump
sounds. ÂLack of oil. ÂAdd oil.
ÂOil inlet pipe sucks air. ÂRepair.
ÂInsufficient air bleeding. ÂBleed air completely.
6. Valve or valve unit makes Oil pump
abnormal sounds. ÂOil inlet pipe sucks air. ÂRepair or replace.
Valve
ÂFaulty. (Unbalance oil pressure) ÂAdjust valve set pressure and check
specified oil pressure.
Piping
ÂPipe (from pump to power steering) ÂRepair or replace.
dented or clogged.
ÂInsufficient air bleeding. ÂBleed air completely.
7. Insufficient or variable oil ÂFlow control valve orifice clogged. ÂClean.
flow.
8. Insufficient or variable dis- Piping
charge pressure. ÂPipe (from tank to pipe) dented or ÂRepair or replace.
clogged.

9-7
5. BRAKE SYSTEM

Trouble symptom Probable cause Remedy

1. Insufficient braking force ÂHydraulic system leaks oil. ÂRepair and add oil.
ÂHydraulic system leaks air. ÂBleed air.
ÂDisk worn. ÂReplace
ÂBrake valve malfunctioning ÂRepair or replace.
ÂHydraulic system clogged ÂClean.
2. Brake acting unevenly. ÂTires unequally inflated. ÂAdjust tire pressure.
(Truck is turned to one ÂBrake out of adjustment. ÂAdjust.
side during braking.) ÂDisk surface roughened. ÂRepair by polishing or replace.
ÂWheel bearing out of adjustment. ÂAdjust or replace.
ÂHydraulic system clogged. ÂClean.
3. Brake trailing. ÂPedal has no play. ÂAdjust.
ÂPiston cup faulty. ÂReplace.
ÂBrake valve return port clogged. ÂClean.
ÂHydraulic system clogged. ÂClean.
ÂWheel bearing out of adjustment. ÂAdjust or replace.
4. Overheat ÂCooling oil insufficient. ÂAdd.
ÂCooling system malfunctioning. ÂRepair or replace.
ÂExcessive braking. ÂUse engine brake.

9-8
6. HYDRAULIC SYSTEM

Trouble symptom Probable cause Remedy

1. Large fork lowering speed. ÂSeal inside control valve defective. ÂReplace spool or valve body.
ÂOil leaks from joint or hose. ÂReplace.
ÂSeal inside cylinder defective. ÂReplace packing.
2. Large spontaneous tilt of ÂTilting backward : Check valve defec- ÂClean or replace.
mast. tive.
ÂTilting forward : tilt lock valve defect- ÂClean or replace.
ive.
ÂOil leaks from joint or hose. ÂReplace.
ÂSeal inside cylinder defective. ÂReplace seal.
3. Slow fork lifting or slow ÂLack of hydraulic oil. ÂAdd oil.
mast tilting. ÂHydrauic oil mixed with air. ÂBleed air.
ÂOil leaks from joint or hose. ÂReplace.
ÂExcessive restriction of oil flow on ÂClean filter.
pump suction side.
ÂRelief valve fails to keep specified ÂAdjust relief valve.
pressure.
ÂPoor sealing inside cylinder. ÂReplace packing.
ÂHigh hydraulic oil viscosity. ÂChange to SAE10W, class CF engine
oil.
ÂMast fails to move smoothly. ÂAdjust roll to rail clearance.
ÂOil leaks from lift control valve spool. ÂReplace spool or valve body.
ÂOil leaks from tilt control valve spool. ÂReplace spool or valve body.
4. Hydraulic system makes ÂExcessive restriction of oil flow pump ÂClean filter.
abnormal sounds. suction side.
ÂGear or bearing in hydraulic pump ÂReplace gear or bearing.
defective.
5. Control valve lever is locked ÂForeign matter jammed between sp- ÂClean.
ool and valve body.
ÂValve body defective. ÂTighten body mounting bolts uniform-
ly.
6. High oil temperature. ÂLack of hydraulic oil. ÂAdd oil.
ÂHigh oil viscosity. ÂChange to SAE10W, class CF engine
oil.
ÂOil filter clogged. ÂClean filter.

9-9
 10. TESTING AND ADJUSTING
1. ENGINE SYSTEM

1) EASE OF STARTING, NOISE

(1) Set gear shift lever at NEUTRAL.

Forward

Neutral

Reverse

160D7OM45

(2) Turn ON the parking brake switch.

(3) Turn ON start switch, automatically heat-
ing operated. RELEASE
BUTTON
(4) When heater signal lamp goes out, turn
ON
key to START, and start engine.
ö When engine starts, check if it starts START

smoothly, and if it makes any abnormal P ON OFF

noise.

250D7EOM10

2) WHEN ACCELERATOR PEDAL IS DEPRESSED

(1) Check that accelerator pedal does not catch when depressed.
(2) Check that engine speed increases in accordance with amount pedal is depressed.
(3) When doing this, check that engine speed changes without gasping, abnormal noise, abnormal
explosions, or irregular vibration.
(4) Check that exhaust gas is colorless when the engine is idling, and a thin black color when
accelerator pedal is depressed.
(5) Set height of stopper bolt according to following table, then adjust with accelerator rod on trucks
and stopper bolt so that engine speed is within specified range when accelerator pedal is fully
depressed.
(6) Max speed : SEE SECTION 8.SPECIFICATIONS

10-1
3) RADIATOR CAP
(1) Push pressure regulator spring with finger
and check that tension is correct.
(2) Pull negative pressure valve, and check
that it is closed when released.
(3) If packing is damaged, replace whole
radiator cap assembly.

160D7ETA08

4) FUEL FILTER
(1) The fuel filter element cannot be inspected from the outside, so replace it periodically (refer to
page 7-13).
Always use HYUNDAI Forklift genuine parts when replacing the element. After replacing the
element, run the engine and check for oil leakage from the filter mount.
5) ENGINE OIL
(1) Check oil level with dipstick and add oil if necessary.
(2) Check oil for discoloration or deterioration. Change oil if discolored or deteriorated.
(3) Engine oil quantity : See section 8. Specification

6) ENGINE OIL FILTER

The condition of the oil filter element cannot
be inspected from the outside so replace High
the engine oil filter(refer to section Normal
7. Maintenance and lubrication) Low
Use a filter wrench and remove the whole
cartridge assembly.

Oil filter

180D7ETA07

10-2
7) FAN
Move fan backwards and forwards by hand
to check for looseness.
Tighten mounting bolt with a spanner.
Crack

160D7TA11

10-3
2. DRIVE SYSTEM

1) GEAR SHIFT LEVER

(1) Neutral starting
Engine can be started only when the shifting lever is in neutral position.
(2) Shifting FWD/REV lever
Η Forward
Push the lever forward then forward solenoid valve operates and oil comes to forward clutch thus
the truck will run forward.
Θ Reverse
Pull the lever backward then reverse solenoid valve operates and oil comes to reverse clutch thus
the truck will run backward.
2) OIL LEAKAGE
Check that there is no oil leakage from torque converter, transmission or control valve. If oil oozes
out and forms drops, replace packing.

3) ADJUSTMENT OF PEDAL
(1) Accelerator pedal
Pedal operation range is "A". If the range
is differ much from specification, replace
A
the pedal immediately.
ÂPedal angle(A) : 17.5Á

160D7TA01

(2) Brake pedal

ÂAdjust stopper bolt(1) so that pedal
angle is "H".
H
ÂPedal angle(H) : 35Á

(1)

160D7TA04

10-4
(3) Inching pedal
ÂAdjust stopper bolt(1) so that pedal
angle is "H"(voltage : 1Ü0.1V). H m
24m
- Pedal angle(H) : 35Á 20~

ÂWhen fully pedaled, voltage is (3)

controlled to 3.5Ü0.1V.
ÂAdjust bolt(3) so that brake pedal
interconnects with inching pedal
at inching pedal stroke, 20~24mm (0.7 (2)
(1)
9~0.94in). 250D7ETA05

10-5
3. TRAVEL SYSTEM

1) TIRES
(1) Check tire pressure using tire gauge : SEE page 5-3 CHECK BEFORE STARTING ENGINE.
(2) Check visually for cracks and damage to
tread and side wall. If crack or damage is
serious, replace tire.
(3) Wear
Measure tread of pneumatic tires(tires A
with air). Depth of tread must be at least B
1.6mm (0.06in) at point 1/4 across width of
tread. A/Bô4.
1.6 mm Min
(4) Check tire visually for uneven wear, (0.06 in)
stepped wear or any other abnormal
wear. Check also for pieces stuck in tire.
D35ATA15

2) HUB NUTS
Use wrench to check for loose hub nuts.
Tighten any loose hub nuts to specified tightening torque : SEE SECTION 8.SPECIFICATIONS

3) RIM SIDE RING

Check rim side ring for deformation or cracks. Check visually or use crack detection method.
ÂRear rim connecting nut torque : SEE SECTION 8.SPECIFICATIONS

4) STEERING AXLE
(1) Push axle in from one side or measure front to rear clearance with feeler gauge. Check that
clearance is within 2mm. If clearance is more than 2mm, insert shim to reduce clearance to within
0.7mm.
ÂMounting bolt torque : SEE SECTION 8.SPECIFICATIONS
(2) Measure clearance between center pin and bushing. Check that clearance is within 0.5mm(0.02in)
and that there is an oil groove on the bushing.

5) DRIVE AXLE
Check that there is no deformation or crack around mounting bolts of front axle and main frame
and at welds. Check visually or use crack detection method.
Mounting bolt torque : SEE SECTION 8.SPECIFICATIONS

10-6
4. STEERING SYSTEM

1) STEERING WHEEL
Set rear wheels facing straight forward, 30~60mm
(1.2~2.4 in)
then turn steering wheel to left and right.
Measure range of steering wheel
movement before rear wheel starts to
move. Range should be 30 - 60mm at rim
of steering wheel. If play is too large,
adjust at gearbox. Test steering wheel
play with engine at idling. 160D7TA12

2) KNUCKLE
Check knuckle visually or use crack detection method. If the knuckle is bent, the tire wear is
uneven, so check tire wear.

3) STEERING AXLE
(1) Put camber gauge in contact with hub and measure camber. If camber is not within 1Ü0.5Á, rear
axle is bent.
(2) Ask assistant to drive truck at minimum turning radius.
(3) Fit bar and a piece of chalk at outside edge of counterweight to mark line of turning radius.
(4) If minimum turning radius is not within Ü100mm(Ü4in) of specified value, adjust turning angle
stopper bolt.

10-7