Hyundai 50D-9 Manual
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Hyundai 50D-9 Manual

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FOREWORD
FOREWORD
A message to hyundai lift truck operators ----------------------------------------------------------------------- 0-1
Introduction ------------------------------------------------------------------------------------------------------------------------ 0-2
How to use this manual ----------------------------------------------------------------------------------------------------- 0-3
EC regulation approved ---------------------------------------------------------------------------------------------------- 0-5
Safety labels ----------------------------------------------------------------------------------------------------------------------- 0-6
Guide (Direction, Serial number, Symbols) --------------------------------------------------------------------- 0-13
1. Daily inspection -------------------------------------------------------------------------------------------------------------- 1-1
2. Do's and don'ts -------------------------------------------------------------------------------------------------------------- 1-2
3. Seat belts ----------------------------------------------------------------------------------------------------------------------- 1-4
4. No riders ------------------------------------------------------------------------------------------------------------------------- 1-5
5. Pedestrians -------------------------------------------------------------------------------------------------------------------- 1-6
6. Operator protection ------------------------------------------------------------------------------------------------------- 1-7
7. Fork safety ------------------------------------------------------------------------------------------------------------------ 1-8
8. Pinch points ---------------------------------------------------------------------------------------------------------------- 1-9
9. Travel ------------------------------------------------------------------------------------------------------------------------------ 1-10
10. Grades, ramps, slopes and inclines ---------------------------------------------------------------------------- 1-11
11. Tip over -------------------------------------------------------------------------------------------------------------------------- 1-12
12. Surface and capacity ---------------------------------------------------------------------------------------------------- 1-14
13. Parking --------------------------------------------------------------------------------------------------------------------------- 1-15
14. Refueling ------------------------------------------------------------------------------------------------------------------------ 1-16
15. Step -------------------------------------------------------------------------------------------------------------------------------- 1-17
16. Operator's safety rules -------------------------------------------------------------------------------------------------- 1-18
17. Side shift ------------------------------------------------------------------------------------------------------------------------ 1-19
1. Loose loads -------------------------------------------------------------------------------------------------------------------- 2-1
2. Long and wide loads ----------------------------------------------------------------------------------------------------- 2-2
3. Rear swing --------------------------------------------------------------------------------------------------------------------- 2-2
4. Low overhead clearance ----------------------------------------------------------------------------------------------- 2-3
5. Fast turns and high loads ---------------------------------------------------------------------------------------------- 2-3
6. Right angle stacking ------------------------------------------------------------------------------------------------------ 2-4
7. Chain slack --------------------------------------------------------------------------------------------------------------------- 2-4
8. Pallets and skids ------------------------------------------------------------------------------------------------------------ 2-5
9. Caution for electrical lines --------------------------------------------------------------------------------------------- 2-5
CONTENTS
CONTENTS

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  • Page 1: Table Of Contents

    CONTENTS CONTENTS FOREWORD FOREWORD A message to hyundai lift truck operators ----------------------------------------------------------------------- 0-1 Introduction ------------------------------------------------------------------------------------------------------------------------ 0-2 How to use this manual ----------------------------------------------------------------------------------------------------- 0-3 EC regulation approved ---------------------------------------------------------------------------------------------------- 0-5 Safety labels ----------------------------------------------------------------------------------------------------------------------- 0-6 Guide (Direction, Serial number, Symbols) --------------------------------------------------------------------- 0-13 1. SAFETY HINTS 1.
  • Page 2 10. Lifting loads -------------------------------------------------------------------------------------------------------------------- 2-6 11. Side shift ------------------------------------------------------------------------------------------------------------------------- 2-6 12. Fork positioner --------------------------------------------------------------------------------------------------------------- 2-8 3. KNOW YOUR TRUCK 3. KNOW YOUR TRUCK 1. General locations ----------------------------------------------------------------------------------------------------------- 3-1 2. Data/safety plate and decal ------------------------------------------------------------------------------------------ 3-2 3. Cab devices ------------------------------------------------------------------------------------------------------------------- 3-4 4.
  • Page 3 6. EMERGENCY STARTING AND TOWING 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 7. PLANNED MAINTENANCE AND LUBRICATION 1. Introduction -------------------------------------------------------------------------------------------------------------------- 7-1 2.

  • Page 4: A Message To Hyundai Lift Truck Operators

    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.

  • Page 5: Introduction

    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.

  • Page 6: How To Use This Manual

    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.
  • Page 7 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.

  • Page 8: Ec Regulation Approved

    EC REGULATION APPROVED EC REGULATION APPROVED · Noise level (2000/14/EC and EN 12053) are as followings. Model (EU only) 50/60/70D-9 106 dB 80 dB 80D-9 107.2 dB 78.6 dB ·The value of vibrations transmitted by the operator's seat are lower than standard value of (2005/88/EC)

  • Page 9: Safety Labels

    SAFETY LABELS SAFETY LABELS 1. LOCATION 1. LOCATION Always keep these labels clean. If they are lost or damaged, attach them again or replace them with a new label. DASHBOARD COVER 42 41 FAN SHROUD RCV LEVER SECTION A-A SECTION B-B 50D9OM101 Logo 11 Operator safety...
  • Page 10 2. DESCRIPTION 2. DESCRIPTION There are several specific warning labels on this truck please become familiarized with all warning labels. Replace any safety label that is damaged, or missing. 1) 1) MAST WARNING MAST WARNING (ltem 2) This warning label is positioned on the left and right side of the mast.
  • Page 11 HAND CAUTION HAND CAUTION (Item 3) This warning label is positioned on the top side of mast. It warns of the danger of injury from It warns of the danger of injury from m o v e m e n t b e t w e e n r a i l s , c h a i n s , m o v e m e n t b e t w e e n r a i l s , c h a i n s , sheaves, fork carriage, and other parts of sheaves, fork carriage, and other parts of...
  • Page 12 START WARNING START WARNING (Item 12) This warning label is positioned on the middle side of dashboard cover. 5 6’ ※ Start key switch after 5~6 seconds from Start key switch after 5~6 seconds from 92AD-00920 O N p o s i t i o n . I t n e e d s a p p r o x 5 ~ 6 O N p o s i t i o n .
  • Page 13 A special air bleed valve is accumulator. A special air bleed valve is necessary for this operation, so please necessary for this operation, so please contact your Hyundai distributor. contact your Hyundai distributor. 0-10...
  • Page 14 OPERATOR SAFETY OPERATOR SAFETY (Item 11) This warning label is positioned on the cabin's upper-left side frame. ① Refer to operator's manual in detail. ② Always buckle up the seat belt for safety operation. ③ When the operator get off the truck, always pull the parking brake lever so that the truck can keep with stopping condition.
  • Page 15 TILT CABIN WARNING TILT CABIN WARNING (Item 21) This warning label is positioned on the left side of frame. Refer to page 7-18 for safe tilting Refer to page 7-18 for safe tilting procedure. procedure. 50D7EFW04 FIRE EXTINGUISHER FIRE EXTINGUISHER (Item 27) T h i s l a b e l i s a d h e r e d o n t h e f i r e extinguisher.

  • Page 16: Guide (Direction, Serial Number, Symbols)

    GUIDE GUIDE 1. DIRECTION 1. DIRECTION The directions of this truck indicate forward, Front backward, right and left when truck is in the travelling direction. Left Right Rear 50D9SM01 2. SERIAL NUMBER 2. SERIAL NUMBER Inform following when you order parts or the truck is out of order. 1) 1) TRUCK SERIAL NUMBER TRUCK SERIAL NUMBER...

  • Page 17: Safety Hints

    1. SAFETY HINTS 1. SAFETY HINTS 1. DAILY INSPECTION 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.

  • Page 18: Do's And Don'ts

    2. DO'S AND DON'TS 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. 50D9OM04 Don't smoke in NO SMOKING areas or when refueling. D35AOM06...
  • Page 19 Don't operate the truck outdoors in rainy day. ※Exclude the truck equipped cabin. Exclude the truck equipped cabin. 50D9OM07 Exhaust gas is dangerous. Do not operate the truck at the inhouse, if possible. Provide adequate ventilation when working in a closed space. 50D9OM08...

  • Page 20: Seat Belts

    3. SEAT BELTS 3. SEAT BELTS Always buckle up for the truck equipped Always buckle up for the truck equipped with safety belt. with safety belt. 22D9TOM09 Seat belts can reduce injuries. Seat belts can reduce injuries. 22D9TOM10...

  • Page 21: No Riders

    4. NO RIDERS 4. NO RIDERS The operator is the only one who should be on a truck. 50D9OM12 Never transport personnel on the forks of a lift truck. 50D9OM14...

  • Page 22: Pedestrians

    5. PEDESTRIANS 5. PEDESTRIANS 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. 50D9OM05 Watch for people in your work area even if your truck has warning lights or alarms.

  • Page 23: Operator Protection

    6. OPERATOR PROTECTION 6. OPERATOR PROTECTION Stay inside the cabin. Always keep your body within the confines of the truck. Do not operate truck without cabin or Do not operate truck without cabin or overhead guard, unless condition prevent overhead guard, unless condition prevent use of it.

  • Page 24: Fork Safety

    7. FORK SAFETY 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. 50D9OM14 Always lower the load slowly. Raise and lower with mast vertical or tilted slightly back(Never forward).

  • Page 25: Pinch Points

    8. PINCH POINTS 8. PINCH POINTS Keep hands, feet and legs out of the Keep hands, feet and legs out of the mast. mast. D255OM61 Don't use the mast as a ladder. Don't use the mast as a ladder. 50D9OM62 Never try to repair the mast, carriage, Never try to repair the mast, carriage, chain, or attachment by yourself.

  • Page 26: Travel

    9. TRAVEL 9. TRAVEL 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 Never lift or lower the load when the truck is in motion. truck is in motion.

  • Page 27: Grades, Ramps, Slopes And Inclines

    10. GRADES, RAMPS, SLOPES AND INCLINES 10. GRADES, RAMPS, SLOPES AND INCLINES Never turn on a grade, either loaded or unloaded. Never turn on a grade, either loaded or unloaded. Unloaded-Forks downgrade 50D9OM30 Loaded - Forks upgrade 50D9OM33 1-11...

  • Page 28: Tip Over

    11. TIP OVER 11. TIP OVER 1) 1) LATERAL TIP OVER LATERAL TIP OVER L a t e r a l t i p o v e r c a n o c c u r w i t h a combination of speed and sharpness of turn.
  • Page 29 3) 3) WHAT TO DO IN CASE OF A TIP OVER WHAT TO DO IN CASE OF A TIP OVER If your truck starts to tip over, do not If your truck starts to tip over, do not jump. jump. Brace yourself as illustrated right.

  • Page 30: Surface And Capacity

    12. SURFACE AND CAPACITY 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. Know the weight of your truck and load. Especially when using elevators, know Especially when using elevators, know the capacity of the elevator you intend to...

  • Page 31: Parking

    13. PARKING 13. PARKING Never park on a grade. 50D9OM41 Always come to a complete stop before leaving the truck. Be sure the travel control is in NEUTRAL. 50D9OM42 Lower forks fully to floor and tilt forward. 50D9OM44 Set the parking brake. Position 1 : OFF(Release) Position 2 : ON(Lock) Turn key to OFF position.

  • Page 32: Refueling

    14. REFUELING 14. REFUELING Before adding oil, check around the truck for oil leakage. 50D9OM47 Keep away from fire when adding oil or during operation. 50D7AOM48 After adding oil, wipe off any oil spilled on the truck. 50D9OM49 1-16...

  • Page 33: Step

    15. STEP 15. STEP When getting on or off the truck, use the step provided. 50D9OM50 Do not jump up or down from the truck. 50D9OM52 1-17...

  • Page 34: Operator's Safety Rules

    16. OPERATOR'S SAFETY RULES 16. OPERATOR'S SAFETY RULES All operational functions require that the operator be seated in the operator's seat. Always buckle up if a seat belt is Always buckle up if a seat belt is provided. provided. 50D9OM18 The parking brake must be locked in the PARK POSITION before exiting from the truck.

  • Page 35: Side Shift

    17. SIDE SHIFT SIDE SHIFT Do not put side loads on the forks. Do not put side loads on the forks. 50D91SS01 Restrict the sideshift movement with Restrict the sideshift movement with raised load. raised load. Abrupt sideshifting under such condition will dramatically reduce the stability of the truck and may cause over-turning.

  • Page 36: Operating Hazards

    2. OPERATING HAZARDS 2. OPERATING HAZARDS 1. LOOSE LOADS 1. LOOSE LOADS L o o s e o r u n b a l a n c e d l o a d s a r e L o o s e o r u n b a l a n c e d l o a d s a r e dangerous.

  • Page 37: Long And Wide Loads

    2. LONG AND WIDE LOADS 2. LONG AND WIDE LOADS With long or wide loads, you need more With long or wide loads, you need more room. So slow down and watch your room. So slow down and watch your clearance.

  • Page 38: Low Overhead Clearance

    4. LOW OVERHEAD CLEARANCE 4. LOW OVERHEAD CLEARANCE Know the height of your truck, with and Know the height of your truck, with and without a load. Check your clearances. without a load. Check your clearances. Keep the load low and tilted back. Keep the load low and tilted back.

  • Page 39: Right Angle Stacking

    6. RIGHT ANGLE STACKING 6. RIGHT ANGLE STACKING When right angle stacking or moving with When right angle stacking or moving with a raised load to clear low objects, avoid a raised load to clear low objects, avoid sharp turns and move slowly. sharp turns and move slowly.

  • Page 40: Pallets And Skids

    8. PALLETS AND SKIDS 8. PALLETS AND SKIDS Do not move or store materials on Do not move or store materials on damaged pallets or skids. Items can fall damaged pallets or skids. Items can fall through them causing severe injury or through them causing severe injury or death.

  • Page 41: Lifting Loads

    10. LIFTING LOADS 10. LIFTING LOADS Never permit any persons to stand or pass under lifted load. 50D9OM58 Never use wire rope to lift a load. 50D9OM60 11. SIDE SHIFT 11. SIDE SHIFT Never operate the side shift while the forks are not equipped with supports such as a load table for the load.
  • Page 42 It should be observed that the side shift with load is operated in netural position before traveling. When operating side shift with load, operate slowly so that it can not avoid from dropping of the load or overturning of the forklift.

  • Page 43: Fork Positioner

    12. FORK POSITIONER 12. FORK POSITIONER Do not operate the fork positioner with a load, or with the fork arm on the ground. Never move the levers to operate the Never move the levers to operate the fork positioner suddenly and quickly. fork positioner suddenly and quickly.

  • Page 44: Know Your Truck

    3. KNOW YOUR TRUCK 1. GENERAL LOCATIONS 50D9OM54 Mast Head lamp 17 Beacon lamp (opt) Lift chain 10 Rear work lamp (opt) 18 Camera (opt) Lift cylinder 11 Operator's seat 19 Silencer Carriage & backrest 12 Bonnet 20 Pre-cleaner Tilt cylinder 13 Counterweight 21 Air conditioner (opt) Forks...

  • Page 45: Data/Safety Plate And Decal

    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. 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.
  • Page 46 OPERATOR SAFETY WARNING DECAL 50D9OM59 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.

  • Page 47: Cab Devices

    3. CAB DEVICES The ergonomically designed console box and suspension type seat provide the operator with comfort. ELECTRONIC MONITOR SYSTEM The centralized electronic monitor system allows the status and conditions of the truck to be monitored at a glance. It is equipped with a safety warning system for early detection of truck malfunction. Front Rear Cluster...

  • Page 48: Cluster

    4. CLUSTER STRUCTURE The cluster consists of gauges, lamps, buttons and LCD 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 lamps : Indicate abnormality of the truck.
  • Page 49 GAUGE Speed meter The speed meter displays the speed of truck in mph and km/h. - 0~50 km/h - 0~31 mph 50D93CD03K Fuel gauge This gauge indicates the amount of fuel in the fuel tank. Fill the fuel when the indicator moves E point, refuel as soon as possible to avoid running out of fuel.
  • Page 50 WARNING LAMPS DEF low level warning lamp Transmission oil temp warning lamp Engine coolant temp warning lamp Engine check warning lamp Fuel low level warning lamp Battery charge warning lamp Seat belt warning lamp Air cleaner warning lamp Transmission error warning lamp Brake system pressure warning lamp Water in fuel warning lamp Engine oil pressure warning lamp...
  • Page 51 Engine oil pressure warning lamp This lamp comes ON for a while after starting the engine because of the low oil pressure. If the lamp comes ON during engine operation, shut OFF engine immediately. Check oil level. 50D93CD18 Air cleaner warning lamp This lamp operates by the vacuum caused inside when the filter of air cleaner is clogged.
  • Page 52 Immediately pull the truck to a convenient stop. Stop the engine. Investigate the cause. Consult a HYUNDAI dealer to investigate the cause. Do not operate until the cause has been corrected. 50D93CD19...
  • Page 53 50% derate, 30 min. Engine error code 3712 DEF level final derate warning Flash Contact Hyundai service center or dealer. Manual SCR cleaning method Manual SCR cleaning applies if the machine is in a fireproof area and there is no plan to turn off the machine during the SCR cleaning.
  • Page 54 Refer to the page 3-10 for detail. 50D9CD32 (14) Engine stop warning lamp When this warning lamp lights ON, stop the engine immediately and and check the DEF level and related parts of the engine. Please contact your Hyundai service center or local dealer. 50D9CD33 3-11...
  • Page 55 PILOT LAMPS Left turning pilot lamp Right turning pilot lamp Parking brake pilot lamp Head light pilot lamp Expendables replacement indicator lamp Inching pilot lamp Fuel warmer pilot lamp Preheater pilot lamp HEST pilot lamp SCR cleaning inhibit pilot lamp OPSS pilot lamp 50D9CD02-2 When the warning and pilot lamps occur over eight, you can display next lamps by push the...
  • Page 56 Head light pilot lamp This lamp comes ON when the main light switch is operated to 2nd step. 50D9CD07 Preheater pilot lamp 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 coolant temperature, indicating that preheating is completed.
  • Page 57 SCR cleaning inhibit pilot lamp This pilot lamp lights ON when the SCR cleaning switch is pushed inhibit position, therefore automatic and manual SCR cleaning can not occur. It should inhibited, before caused fire due to the exhaust gas in high temperature. Refer to the page 3-37 for the SCR cleaning switch.
  • Page 58 CLUSTER BUTTON Each button has the following function. Menu button Enter button Move button Buzzer stop/ESC button 50D9CD121 Buzzer stop/ESC button This button is used to stop the buzzer sound. If another alarm condition occurs after this button has been pressed, the alarm buzzer will re-sound.
  • Page 59 Main screen You can select or set the menu by the button of the cluster. Please refer to the page 3-15 for the selection and change of the menu and input value. Main screen Main menu screen Sub menu screen MENU 50D9CD10 50D9CD11...
  • Page 60 Main menu Main menu Sub menu Description Model select Model select Tilt setting Tilt setting (mast and vehicle angle) Rear angle setting Rear angle setting Weight sensor setting Cross-section, load weight adjust, weight display setting, load indicator buzzer ESL setting ESL setting Equipment Vehicle max speed limit...
  • Page 61 Equipment Choose the equipment 50D9CD20 50D9CD21 To enter the menu, you must input user password. Default password is ‘00000’ You should set password by fi ve to ten digit. Model select 50D9CD22 50D9CD23 50D9CD24 Select the Model The initial model is selected at the factory, so don’t change the different model.
  • Page 62 Weight sensor setting Cross-section 50D9CD35 50D9CD36 50D9CD37 Enter the designated cross-section (cm Mast spec 50/60/70/80D-9 V mast 113.49 TS mast 141.76 TF mast 132.73 50D9CD38 Load weight adjust Unloaded status adjustment In the unloaded from the ground waiting 5 seconds after lift 30 cm, and tare ON.
  • Page 63 Weight display setting 50D9CD35 50D9CD53 50D9CD54 Select the number of points of weight value display. 50D9CD55 Load indicator buzzer 50D9CD35 50D9CD57 50D9CD58 Choose using buzzer when over weight. ESL setting 50D9CD59 50D9CD60 50D9CD61 50D9CD62 50D9CD63 Set ON/OFF function for using limitation of ignition and time for starting.
  • Page 64 Vehicle max speed limit 50D9CD65 50D9CD66 50D9CD67 Set the maximum speed. 10 km/h~30 km/h (1 km/h intervals) 50D9CD68 50D9CD69 50D9CD70 AEB setting 50D9CD71 50D9CD72 Press OK button, then calibration will be started, for cancel, press Menu/ECS/Enter button. When it is fi nished (OK sign at gear box), Press Menu/ECS/Enter button. Start the engine : AEB start KEY ON : Brake pedal sensor calibration (R) MCU / Cluster information...
  • Page 65 Finger tip setting Lever position setting 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 Ability to set up the maximum Pull, Push (Min,Max) value and neutral value (Mid) of lever. Finger Tip lever set up about 0.5V~2.5V~4.5V. You must be to move with actual Lever.
  • Page 66 Lever deadzone setting 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 Ability to prevent the Value output due to a tiny error of the neutral Lever state (2.5V) ex) If you set up the Upper : 0.26, Lower : 0.24, Lever operating range will be Upper zone : 2.76V (2.5+0.26) ~ 4.5V (Lever Max value) Lower zone : 2.26V (2.5-0.24) ~ 0.5V (Lever Min value)
  • Page 67 Valve setting 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 Current Setting : Current setting for input each Valve Coil, it is to set up each maximum value of movements according ot the current value (Unit % (Over 110D-9 only), mA (Under 80D-9 Only) ex) If the Max value increase, the maximum speed will also increase.
  • Page 68 Maintenance Choose the maintenance 50D9CD75 50D9CD76 To enter the Menu, you must input user password. Default password is ‘00000’ You should set password by fi ve to ten digit. Current failure history 50D9CD77 50D9CD78 50D9CD79 Show the failure status of engine / transmission. 50D9CD80 Maintenance management 50D9CD81...
  • Page 69 Signal status 50D9CD89 50D9CD90 50D9CD91 Display information of each sensors. 50D9CD92 50D9CD93 User password change 50D9CD94 50D9CD95 50D9CD96 You should set password by fi ve to ten digit. 50D9CD97 RMCU Comm 50D9CD98 50D9CD99 50D9CD100 When successfully opened RMCU communication, Except for the RMCU Comm.
  • Page 70 Display setting Choose the display setting No password is required. 50D9CD108 LCD adjustment 50D9CD109 50D9CD110 50D9CD111 50D9CD112 50D9CD113 Manual : Manual setting for LCD brightness. Automatic : Automatic control of LCD brightness as set level of Day/Night. Setting day time : Set the time for daylight. (If you set the time for daylight, the rest time will be night.) 50D9CD114 50D9CD115...
  • Page 71 Unit setting 50D9CD118 50D9CD118-1 50D9CD119 Change units of temperature / speed / wight / pressure. Language setting 50D9CD120 50D9CD121 50D9CD122 Set the language used by your device. (13 Multiple language) 50D9CD123 A/S phone number 50D9CD124 50D9CD125 50D9CD126 Check and change of contact information for customer service. ESL password change 50D9CD127 50D9CD128...
  • Page 72 Maintenance management 50D9CD131 50D9CD132 50D9CD133 Show the maintenance information (replacement cycle, elapsed time, change count, alarm information). 3-26...

  • Page 73: Transmission Message Display

    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. Transmission message display 50D93ACD33 If it happens error codes, consult with Hyundai service center to repair the fault. 3-27...
  • Page 74 Display during operation Symbol Meaning Remarks Actual gear and direction F, N, R Central side shows actual gear 1, 2, 3 Right side shows actual direction Not neutral, waiting for neutral To engage a gear, first move shift selector to neutral (Central and right side) after power up or a severe fault position and again to F to R position...
  • Page 75 Definition of the error codes Introduction The error codes consists of two hexadecimal numbers. The first number shows the type of signal, the second number shows signal and the type of the error. Description of error codes First No. Meaning of number 1 hex Digital input signals 2 hex...
  • Page 76 Number Meaning of error code 3A hex Short circuit to battery voltage or open circuit at output speed input 3B hex Short circuit to ground or open circuit at output speed input 3C hex Logical error at output speed input 71 hex Short circuit to battery voltage at clutch KC 72 hex...
  • Page 77 Meaning of error code Number D1 hex Short circuit to battery voltage at power supply for sensors Short circuit to ground at power supply for sensors D2 hex Low voltage at battery D3 hex D4 hex High voltage at battery D5 hex Error at valve power supply 1 D6 hex...

  • Page 78: Switches

    6. SWITCHES Main light switch Hazard switch(opt) Rear work lamp switch(opt) Beacon lamp switch(opt) Cover Parking brake switch Auto/manual changeover switch Inching switch Fuel warmer switch In/decrement switch SCR cleaning switch Rear wiper/washer switch Top wiper/washer switch(opt) Engine mode switch(opt) Cover Switch panel Start switch...
  • Page 79 START SWITCH 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 HAZARD SWITCH (OPTION) Use for parking, or loading truck.
  • Page 80 REAR WORK LAMP SWITCH (OPTION) This switch is used to operate the work lamps. Press this switch to turn on work lamps. 35D9AOM16 AUTO/MANUAL CHANGEOVER SWITCH Manual mode ( ) Press the top of the switch for the manual mode of the autoshift function.
  • Page 81 FUEL WARMER SWITCH This switch is used to heat the fuel of pre-heater. 35D9AOM19 BEACON SWITCH (OPTION) This switch turn ON the strobe light. 35D9AOM18 INC/DECREMENT SWITCH When engine running, the low rpm of engine increase or decrease by 25 rpm by operating this switch. Engine low rpm returns to normal value when engine restarted.
  • Page 82 CAB LAMP SWITCH This switch turns ON the cab room lamp. 73033CD24 MULTI FUNCTION SWITCH Front wiper and washer switch When the switch is in J position, the wiper moves intermittently. When placed in position, the wiper moves continuously. If you push the grip of the lever, washer liquid will be sprayed and the wiper will be activated 2-3 times.
  • Page 83 SCR (Selective Catalytic Reduction) CLEANING SWITCH This switch is used to select the cleaning function of the SCR. Inhibit position ( ) The inhibit position disallows any automatic or manual SCR cleaning. This may be used by operator to prevent SCR cleaning when the machine is operating in a hazardous environment is concerned 50D9OM21A about high temperature.

  • Page 84: Control Device

    7. CONTROL DEVICE Lift lever Tilt lever Steering wheel 3-spool lever(opt) Gear selector lever 4-spool lever(opt) Inching pedal 5-spool lever(opt) Brake pedal Accelerator pedal 50D9CD08 LIFT LEVER LIFT PULL the lever BACK to LIFT the forks. Lower LOWER PUSH the lever FORWARD to LOWER the load. Lift HOLDING When the lever is released, the lifting or lowering action stops.
  • Page 85 LEVER FOR SIDE SHIFT LH MOVEMENT Push the lever forward to move the left hand for the side shift. RH MOVEMENT Pull the lever backward to move the right hand for the side shift. 50D9CD17 LEVER FOR SIDE SHIFT WITH FORK POSITIONER FORK POSITIONER (SYNCHRONIZER TYPE) OUTSTRECH THE FORKS Outstrech...
  • Page 86 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 50D9CD22 GEAR SELECTOR LEVER This lever is used for gear selection, forward 3 stages and reverse 3 Acceleration stages.
  • Page 87 ACCELERATOR PEDAL This pedal controls the engine speed. The engine speed will increase in proportion to the degree of force applied to this pedal. Unless this pedal is pressed, the truck will run at low idling. 160D7ECD32 INCHING PEDAL Inching pedal is used for fine control of forward and reverse movement when lifting up or putting down loads.

  • Page 88: Air Conditioner And Heater

    8. AIR CONDITIONER AND HEATER Fuel auto air conditioner and heater are equipped for pleasant operation against outside temperature and defrost on window glass. Fan speed control knob Outlet control button Air conditioner button Air inlet control button Temperature control knob Air conditioner switch 50D9CD90 AIR CONDITIONER BUTTON...
  • Page 89 OUTLET CONTROL BUTTON There are five kinds of air flow. Face Rear Face and rear Face and defrost Defrost The pilot lamp is turned ON when the button is pushed. 50D9CD51 TEMPERATURE CONTROL KNOB This knob regulates the temperature of air. Right side (red zone) : Cool down air temperature Left side (blue zone) : Heat up air temperature 50D9CD53...

  • Page 90: Others

    9. OTHERS Front Rear Radio and USB player(option) Monitor(option) Cigar lighter 12V socket Handsfree(option) Remote controller(option) 50D9CD09 CIGAR LIGHTER This can be used when the engine starting switch is ON. The lighter can be used when it springs out in a short while after being pressed down.
  • Page 91 HANDSFREE (OPTION) Allow you to dial a call or to have a conversation without holding your handset. Use the remote controller when making and answering a calls or ring off. Indicator lamp Private call jack socket Handsfree jack socket USB socket Mobile phone stroage box Service socket 21093CD51...
  • Page 92 Handsfree jack socket Connect the jack cable when call by handsfree. Use the special adapter when jack cable is not interchangeable. Check the jack type of mobile phone before use. 21093CD51D Indicator lamp This lamp is turned ON when the handsfree mode selected. 21093CD51E 3-60...
  • Page 93 (connection process of the mobile phone and handsfree), you can Call button hear beep sounds three times. 55I3CD26 The mobile phone finds bluetooth named " HYUNDAI". Select "HYUNDAI" and set "connect with Bluetooth on the mobile phone". HYUNDAI · Default password : 0000 PAIRING 55I3CD27 The Bluetooth pairing is made, the LCD screen shows "CONNECTED".
  • Page 94 REMOTE CONTROLLER (OPTION) Radio handsfree jack External speaker LED (null) External speaker microphone (null) Handsfree jack MIC Power/volume switch External speaker switch (null) Handsfree mode button CALL button SEEK button SEEK button MODE button MUTE button TALK button Radio calling mode button 55I3CD31 Power and volume switch This switch is used to turn the audio or handsfree ON or OFF.
  • Page 95 Handsfree MIC This MIC transfers user voice to receiver of the call when making a call by handsfree. 55I3CD31D Seek button If this button pressed, the radio automatically stops at the next frequency of broadcasting for your listening. This button enable to select the song of the MP3 from USB. : Turn a station of higher frequency and the next song of the MP3.
  • Page 96 Radio calling mode button Press this button, activated or deactivated the radio handsfree function. As long as you do not press this button, you can hear the other party. 55I3CD31H The LED is turned ON when this button is activated. The LED turned OFF when the audio mode or the mobile phone handsfree calling mode is activated.
  • Page 97 MONITOR · Adjusting the angle Upwards and downwards up to 7˚, swivels left and right up to 15˚. Sunshade LCD (7") Buttons 50D9CD211 Symbol Name Description LEFT - Move the Menu (left). Lower the value. - Enter the OSD menu MENU / ENTER - Choose the menu RIGHT...
  • Page 98 Operation CAM set 50D9CD200 50D9CD201 Set the number of camera channels on screen. 1 CH (standard) Display one camera image on screen. Press left or right key to change the camera channel. Rear Front Side 1 Side 2 50D9CD202K 2 CH (dual) Display two camera images on screen.
  • Page 99 Gear linkage mode 50D9CD205 50D9CD206 Depending on the gear state (forward/ backward), camera channel is switched automatically. Brightness setting 50D9CD207 50D9CD208 Adjust the display brightness. Language 50D9CD209 50D9CD210 Set the language (13 multiple language). 3-67...

  • Page 100: Operator Maintenance And Care

    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 Do not operate a truck if it is in need of repair.
  • Page 101 2) 2) FUNCTIONAL CHECKS FUNCTIONAL CHECKS Check the operation of the truck as follows. ※ Before performing these checks, familiarize yourself with the starting, operating, and 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 shutdown procedures in Section 5 of this manual.

  • Page 102: Suggestion For New Truck

    2. SUGGESTION FOR NEW TRUCK 2. SUGGESTION FOR NEW TRUCK It takes about 100 operation hours to enhance its designed performance. Operate according to below three steps and avoid excessive operation for the initial 100 hours. Avoid excessive operation for initial 100 hours Service meter Load...

  • Page 103: Fuel Safety Practices

    3. FUEL SAFETY PRACTICES 3. FUEL SAFETY PRACTICES REFUELING DIESEL TRUCKS 100D7OM106 Stop the engine when refueling. Stop the engine when refueling. All lights and flames shall be kept at a All lights and flames shall be kept at a safe distance while refueling.

  • Page 104: Starting And Operating Procedures

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

  • Page 105: Check Before Operation

    2. CHECK BEFORE OPERATION 2. CHECK BEFORE OPERATION 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.

  • Page 106: Check Before Starting Engine

    CHECK FOR WATER OR OIL LEAKAGE CHECK FOR WATER OR OIL LEAKAGE Walk around your HYUNDAI truck and check for water, oil or hydraulic leakage. Examine truck for obvious damage. Check cabin, backrest and forks for crack or obvious damage.
  • Page 107 3) 3) CHECK COOLANT LEVEL CHECK COOLANT LEVEL If the cooling water in the radiator reservoir tank is not within normal range when cool, add water to the FULL line. Full 50D9OM61 In antifreeze is being used, pay careful attention to the ratio of antifreeze and water when In antifreeze is being used, pay careful attention to the ratio of antifreeze and water when adding coolant.
  • Page 108 5) 5) CHECK FAN BELT CHECK FAN BELT An deflection method can be used to check belt tension by applying 11 kgf (25 lbf) force between the pulleys on V-belts. If the deflection is more than one belt thickness per foot of pulley center distance, the belt tension must be adjusted.
  • Page 109 7) 7) CHECK BATTERY CHECK BATTERY Battery maintenance need serious care and safety service. Battery maintenance need serious care and safety service. Refer to 10. REPLACEMENT AND CHECK in SECTION 7. Refer to 10. REPLACEMENT AND CHECK in SECTION 7. and always keep the safety rules.
  • Page 110 MULTI FUNCTION SWITCH MULTI FUNCTION SWITCH Front wiper and washer switch Front wiper and washer switch O J Ⅰ Ⅱ ① When the switch is in J position, the wiper moves intermittently. ② When placed in Ⅰ or Ⅱ position, the wiper moves continuously. ③...

  • Page 111: Seat Adjustment

    4. SEAT ADJUSTMENT 4. SEAT ADJUSTMENT 1) 1) SEAT ADJUSTMENT SEAT ADJUSTMENT The seat adjustable to fit the contours of the operator's body. It will reduce operator fatigue due to long works hours and enhance work efficiency. Grammer seat Grammer seat (1) (1) Forward/Backward adjustment (A) Forward/Backward adjustment (A)

  • Page 112: Starting From A Safe Condition

    5. STARTING FROM A SAFE CONDITION 5. STARTING FROM A SAFE CONDITION Always start from a safe condition. Before operating a lift truck, make sure that : · You are safely seated in the truck. Set the parking brake · Seat belt is buckled up.

  • Page 113: General Starting And Operating Tips

    6. GENERAL STARTING AND OPERATING TIPS 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.

  • Page 114: Starting And Stopping The Engine

    7. STARTING AND STOPPING THE ENGINE 7. STARTING AND STOPPING THE ENGINE 1) 1) CHECK INDICATOR LIGHTS CHECK INDICATOR LIGHTS Gear selector lever Check if parking brake switch is LOCK position. Check if gear selector lever is in neutral position. Parking brake switch Turn the key to the ON position, and check following.
  • Page 115 3) 3) STARTING ENGINE IN A COLD WEATHER STARTING ENGINE IN A COLD WEATHER ※ Sound horn to warn surroundings after Sound horn to warn surroundings after checking if there are obstacles in the area. checking if there are obstacles in the area. ※...
  • Page 116 Check engine exhaust color. Exhaust gas color Criteria Colorless, light blue Black Check for incomplete combustion White Check for oil leakage Check fuel tank level. If the indicator points to F, the tank is full. If the indicator enters the E range, refill the fuel tank immediately. Do not operate the truck below this level.
  • Page 117 (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) 5) TRANSMISSION COLD STARTING TRANSMISSION COLD STARTING At an oil temperature in the shifting circuit...

  • Page 118: Warming-Up Operation

    8. WARMING-UP OPERATION 8. WARMING-UP OPERATION ※ The most suitable temperature for the hydraulic The most suitable temperature for the hydraulic Gear selector lever oil is about 50 oil is about 50˚C C (112 (112˚F ). F ). It can cause serious trouble in the hydraulic It can cause serious trouble in the hydraulic s y s t e m b y s u d d e n o p e r a t i o n w h e n t h e s y s t e m b y s u d d e n o p e r a t i o n w h e n t h e...

  • Page 119: Levers And Pedals

    9. LEVERS AND PEDALS 9. LEVERS AND PEDALS 1) 1) POSITIONING FORKS AND MAST 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.
  • Page 120 2) 2) SELECTING DIRECTION OF TRAVEL 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. Reverse 160D7OM95 3) 3) USING THE ACCELERATOR PEDAL USING THE ACCELERATOR PEDAL With the parking brake released and the direction control in FORWARD or REVERSE, put your foot on the accelerator...

  • Page 121: Traveling Of The Truck

    10. TRAVELING OF THE TRUCK 10. TRAVELING OF THE TRUCK 1) 1) BASIC OPERATION BASIC OPERATION Tilt back fully (1) (1) Traveling posture Traveling posture Lift the forks so that the forks are placed 15~ 20 cm (6~8 in) above the ground and tilt back the mast fully.
  • Page 122 When traveling at high speed, do not When traveling at high speed, do not abruptly decelerate by using the trans- abruptly decelerate by using the trans- mission lever, to slow down instead press mission lever, to slow down instead press the brake pedal.
  • Page 123 (6) (6) Stopping the truck Stopping the truck ① Press the brake pedal to stop the truck. Gear selector lever ② Put the gear selector lever in the neutral position. Parking brake switch ③ Turn the parking brake switch ON. 50D9OP14 ④...
  • Page 124 (7) (7) Stopping engine Stopping engine Gear selector lever ※ If the engine is abruptly stopped before it has If the engine is abruptly stopped before it has c o o l e d d o w n , i t s s e r v i c e l i f e m a y b e c o o l e d d o w n , i t s s e r v i c e l i f e m a y b e Parking brake switch shortened.

  • Page 125: Operating Safely

    11. OPERATING SAFELY 11. OPERATING SAFELY Safe operation is the responsibility of the operator. WATCH WHERE YOU ARE GOING. DON’T GO IF YOU CAN’T SEE... WATCH WHERE YOU ARE GOING. DON’T GO IF YOU CAN’T SEE... 1) 1) Before driving, check all around to be sure that your intended path of travel is clear of obstructions and pedestrians.
  • Page 126 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. Do not elevate the load except during stacking. 5) 5) GRADES, RAMPS, AND INCLINES...

  • Page 127: Load Handling

    12. LOAD HANDLING 12. LOAD HANDLING 1) 1) GENERAL 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.
  • Page 128 2) 2) ADJUSTING THE LOAD FORKS 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.
  • Page 129 4) 4) TRAVELING WITH LOAD 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.
  • Page 130 5) 5) PICKING UP AND MOVING LOADS 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.
  • Page 131 7) 7) STACKING STACKING To put a load on a stack To put a load on a stack (1) (1) ① Aproach slowly and align the lift truck and load squarely with the stack. D35AOM137 ② Raise the load as the lift truck nears the stack. D35AOM138 ③...
  • Page 132 (2) (2) To move a load from a stack 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.

  • Page 133: Shut Down Procedure

    13. SHUT DOWN PROCEDURE 13. SHUT DOWN PROCEDURE ※ Always leave your lift truck in a safe condition. Always leave your lift truck in a safe condition. 1) 1) WHEN YOU LEAVE YOUR TRUCK, OR PARK IT, FOLLOW THESE SAFETY RULES WHEN YOU LEAVE YOUR TRUCK, OR PARK IT, FOLLOW THESE SAFETY RULES Park in a safe area away from normal traffic.

  • Page 134: Storage

    14. STORAGE BEFORE STORAGE When you keep your forklift truck in storage for an extended period of time, observe the following safeguard instructions: Wash and tidy the truck and house it in a dry building. When the truck has to be placed outdoors, park it on a even ground and cover it securely with canvas.

  • Page 135: Transport

    PRECAUTIONS FOR LOADING AND UNLOADING 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.

  • Page 136: Loading And Unloading By Crane

    16. LOADING AND UNLOADING BY CRANE Check the specification of the truck when you are going to hoist the truck. Use long wire rope and stay to keep the distance with the machine as it should avoid touching with Stay Wire rope the truck body.

  • Page 137: Emergency Starting And Towing

    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). Use an approved, solid metal tow bar with towing couplers that connect to the towing pins in the counterweights.
  • Page 138 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. Set the parking brake switch the ON (LOCK) position. Remove the key and, when necessary, block the wheels to prevent the truck from rolling.
  • Page 139 2. PARKING BRAKE RELEASE 2. PARKING BRAKE RELEASE In case of malfunction of transmission, it's hard to supply pressure at parking brake. Using function of parking force release at carrier sub assembly of drive axle, it is possible to tow the truck.

  • Page 140: How To Use Battery Jumper Cables

    3. HOW TO USE BATTERY JUMPER CABLES 3. 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.
  • Page 141 Connect the jumper cables in the following To ground sequence: To starter switch ⓐ Connect a jumper cable from the positive Charged battery (+; red) terminal on one battery to the positive (+; red) terminal on the other battery. Never connect positive (+; red) to negative (-;...

  • Page 142: Planned Maintenance And Lubrication

    Specifications for selected components, fuel, lubricants, critical bolt torques, refill capacities, and settings for the truck are found in section 8. If you have needed for more information on the care and repair of your truck, see your HYUNDAI dealer.

  • Page 143: Safe Maintenance Practices

    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. Powered industrial trucks can become hazardous if maintenance is neglected. Therefore, suitable maintenance facilities and trained personnel and procedures shall be provided.
  • Page 144 Before leaving the truck. Stop the truck. Fully lower the load-engaging means: mast, carriage, forks or attachments. Put the directional control in NEUTRAL. Apply the parking brake. Stop the engine. Turn the key switch to the OFF position. Put blocks at the wheels if the truck must be left on an incline. 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.
  • Page 145 Parts, including tires, are to be installed per the manufacturer's procedures. Always use genuine HYUNDAI or HYUNDAI-approved parts. When removing tires follow industry safety practices. Most importantly, deflate pneumatic tires completely prior to removal.

  • Page 146: Instructions Before Maintenance

    3. INSTRUCTIONS BEFORE MAINTENANCE INTERVAL OF MAINTENANCE You may inspect and service the truck by the period as described at based on service meter of LCD. Shorten the interval of inspect and service depending on site condition.(Such as dusty area, quarry, sea shore and etc.) Practice the entire related details at the same time when the service interval is doubled.
  • Page 147 Engine and hydraulic components have been preset in the factory. Do not allow unauthorized personnel to reset them. Ask to your local dealer or Hyundai for maintenance advise it unknown. 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.
  • Page 148 Replace clamp at the same time if the hose clamp is cracked when checking and replacing hose. EMISSION-RELATED COMPONENTS WARRANTY (USA AND CANADA ONLY) Hyundai shall have obligation under the EPA (Environmental Protection Agency) regulation of warranty about Emission-related components. This warranty shall exist for 3,000 hours or five years, whichever occurs first.

  • Page 149: Planned Maintenance Intervals

    4. PLANNED MAINTENANCE INTERVALS MAJOR COMPONENTS LOCATION 9 10 11 15 12 14 50D9OM21 Mast Transmission 17 Air cleaner Lift cylinder 10 Torque converter 18 Radiator Steering unit 11 Engine 19 Seat Tilt cylinder 12 Steering cylinder 20 Cabin Main control valve 13 Hydraulic pump 21 Steering wheel Fork...
  • Page 150 MAINTENANCE CHECK LIST Every 10 hours service Check items Service Remarks Visual inspection Truck for obvious damage and leaks. Check, Repair or Replace 7-15 Warning plates and decals. Check, Replace 7-15 Condition of tires and air pressure, wheels & nuts. Check, Refill or Tighten 7-17 Lift chain and fastener.
  • Page 151 Initial 50 hours service Initial 50 hours service Check items Service Remarks Engine oil Change 7-20 Engine oil filter Replace 7-20 Pilot line filter element Replace 7-35 Initial 100 hours service Initial 100 hours service Check items Service Remarks Differential gear oil Change 7-42 Differential gear oil strainer...
  • Page 152 Aftertreatment DEF dosing unit filter Replace 7-31 Urea level sensor suction filter Replace 7-31 (10) (10) Every 5000 hours service Every 5000 hours service Check items Service Remarks Hydraulic oil (* Replace 7-34 Hyundai genuine long life hydraulic oil 7-11...
  • Page 153 (11) When required Check items Service Remarks Fuel system Fuel tank 7-29 Drain or Clean Prefilter 7-29 Drain or Clean Fuel filter 7-30 Replace Engine lubrication system Engine oil 7-20 Replace Engine oil filter cartrige 7-20 Replace Engine cooling system Coolant 7-22 Refill, Replace...

  • Page 154: Maintenance Chart

    5. MAINTENANCE CHART MAINTENANCE LOCATIONS 50D9MA011 CAUTION Service intervals are based on the hourmeter reading. Stop the engine when servicing. Do not open the cap or drain plug to avoid injury by unexpected spouting of high temperature fluid or gas. Open the cap slowly to relieve pressure.
  • Page 155 30 Urea level sensor suction filter Replace 5000 Hours 21 Hydraulic oil Change Conventional hydraulic oil Hyundai genuine long life hydraulic oil Oil symbol ※ Refer to the recommended lubricants for specification. DF : Diesel fuel HO : Hydraulic oil...

  • Page 156: How To Perform Planned Maintenance

    6. HOW TO PERFORM PLANNED MAINTENANCE 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.
  • Page 157 FORKS Inspect the load forks for cracks, breaks, bending, and wear. The fork top surfaces should be level 10% of "A" is and even with each other. The height difference max. wear allowed between both fork tips refer to below table. Fork length Height Model...
  • Page 158 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.
  • Page 159 TILTING CABIN Keep clearance of people except the operator before tilting the cabin. Before tilting the cabin, make sure that the mast is vertical or tilted forward. Otherwise, the operation could be blocked by mast tilt cylinders. Locate the truck on the plain and stable floor. Apply parking brake before servicing.
  • Page 160 Do not operate cabin tilting function while the power is ON or engine is running. START 160D7MI65 Do not operate the cabin tilt switch or any control parts while servicing under the tilted cabin. It can cause severe injury or death. WARN OPERATE 50D96MI64...

  • Page 161: Service Instruction

    7. SERVICE INSTRUCTION CHECK ENGINE OIL LEVEL Check the oil level with the truck on a flat ground Dipstick before starting engine. Pull out the dipstick and wipe with a clean cloth. Check the oil level by inserting the dipstick completely into the hole and pulling out again.
  • Page 162 Apply a light film of lubricating oil to the gasket sealing surface before installing the filter. Fill the filter with clean lubricating oil. The lack of lubrication during the delay until the filter is pumped full of the start-up can damage the engine.
  • Page 163 CHECK COOLANT LEVEL Check the coolant level at reservoir tank. Add the mixture of antifreeze and water after if coolant is not sufficient. The coolant level should indicate between Full and Low. Replace gasket of surge tank cap when it is damaged.
  • Page 164 FLUSHING AND REFILLING OF RADIATOR 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. 80D9MI31 Protect the environment : Handling and disposal of used antifreeze can be subject to...
  • Page 165 During filling, air must be vented from the engine coolant passages. The system must be filled slowly to prevent air locks or serious engine damage can result. Wait 2 to 3 minutes to allow air to be vented, then add mixture to bring the level to the top.
  • Page 166 Cooling system filling Use a mixture of 50 percent water and 50 percent ethylene glycol antifreeze to fill the cooling system. Refer to the page 7-64. Use the correct amount of DCA4 corrosion inhibitor to protect the cooling system. Do not use hard water such as river water or well water.
  • Page 167 Visually inspect the radiator for core leaks. 50D96MI02 CHECK CHARGE AIR COOLER Inspect the charge air cooler for dirt and debris blocking the fins. Check for cracks, holes, or other damage. If damage is found, please con- tact Hyundai distributor. 50D96MA21 7-26...
  • Page 168 FAN BELT TENTIONER With the engine stopped, check the tensioner arm, pulley, and stops for cracks. If any cracks are found, the tensioner must be replaced. 2609A6MA23 With the belt installed, verify that neither tensioner arm stop is in contact with the spring case stop.
  • Page 169 CLEANING OF AIR CLEANER Primary element Open the cover and remove the element. Wipe all contaminant and debris from inside the housing body. Do not clean the filter element by striking or hitting the filter against any object to shake the debris from the filter element.
  • Page 170 FUEL TANK Fill fuel fully when system the operation to Fuel Cap minimize water condensation, and check it with fuel gauge before starting the machine. Fuel tank Drain the water and sediment in the fuel tank by opening the drain cock. Be sure to LOCK the cap of fuel tank.
  • Page 171 REPLACEMENT OF FUEL FILTER Remove the fuel filter cartridge (1) with 32 mm hex wrench. Apply a thin layer of fuel to the surface of the new filter cartridge gasket before you put it on. Tighten the new cartridge by hand. Open the fuel valve and bleed the fuel system.
  • Page 172 A F T E RT R E AT M E N T D I E S E L E X H AU S T FLUID DOSING UNIT FILTER Remove There may be residual DEF in the filter housing. A collection container placed below the DEF filter cap is recommended.
  • Page 173 Clean the aftertreatment DEF dosing unit cap and threads on the dosing unit with warm water and a clean cloth. Never operate the truck with the DEF cap removed. 250D9DEF03 Install Slide the DEF filter equalizing element (2) into the DEF filter cartridge (3). Insert the assembly into the aftertreatment DEF dosing unit.
  • Page 174 If the DEF/AdBlue ® level is found to below, DEF/ ® AdBlue must be added. Before filling the tank Switch off the engine. Secure the truck against rolling away. Always fill the tank with at least 5 liters, as smaller amounts could cause malfuctions.
  • Page 175 FILLING HYDRAULIC OIL Air breather Stop the engine to the position of level check. Check air breather filter element and replace it if necessary. Loosen cap and fill the oil to the specified level. Bolt Start engine after filling and operate the work equipment several times.
  • Page 176 CLEANING AND REPLACING RETURN FILTER Clean and replace the return filter in the following Return manner. filter Flange Remove the flange by loosening the mounting bolt. Remove the return filter from the tank. Replace the return filter element with a new one. Install the cover on the tank.
  • Page 177 CLEANING BRAKE LINE FILTER Cut-off valve Remove the strainer from the filter body. Wash the strainer with cleaning oil. Install and tighten with specified torque. Tightening torque : 4.5~5.5 kgf m (32.5~39.8 lbf ft) 50D9MI24 LUBRICATE RCV LEVER Bellows Remove bellows and grease the joint (A) and the sliding parts (B).
  • Page 178 TIRE PRESSURE 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. Recommended tire pressure (When tire is cooled) Model Size...
  • Page 179 Do not use recycled wheel parts. When removing lockering or inflating tire, use safety cable or chain to ensure safety. B e s u r e t o bl e e d a i r b e fo r e r e m ov i n g lockering.
  • Page 180 Loosen slightly all wheel mounting. Tools : Socket 32mm Torque wrench Extension bar Lift the truck with a jack. Loosen all wheel mounting nuts and replace the tire. Torque wrench 160D7MI37 Direction of tire to be installed Be careful that the valve should be facing the outside.
  • Page 181 CHECK TRANSMISSION OIL LEVEL The oil level check must be carried out as follows; Oil level check (weekly). At horizontally standing the truck. Transmission in neutral position. In cold start phase, the engine must be running about 2~3 minutes at idling speed, and the marking on the oil level gauge must then be lying above the cold start mark COLD.
  • Page 182 Remove the transmission oil filter cartridge. Dispose of the used transmission oil filter cartridge properly. Clean the filter cartridge mounting base. Transmission oil filter Remove any part of the filter cartridge gasket that remains on the filter cartridge mounting base. 50D7AMI43 Apply a light coat of oil to the gasket of a new transmission oil filter cartridge.
  • Page 183 CLEANING TRANSMISSION AIR BREATHER CLEANING TRANSMISSION AIR BREATHER Remove dust or debris around the air breather. Air breather Remove the air breather and wash it with the cleaning oil. 50D7AMI45 DIFFERENTIAL CASE DIFFERENTIAL CASE (1) (1) Differential oil Differential oil Park the truck in a level place.
  • Page 184 LUBRICATION Supply grease through the grease nipple, using the grease gun. After lubricating, clean off spilled grease. Apply the parking brake and fix the front and rear tires with blocks. Set the mast and forks in a stable position. Lubrication points Adjust cylinder : 2EA Forks : 2EA 1 Adjust cylinder(2EA)
  • Page 185 MAINTENANCE OF WORK EQUIPMENT Lubricate to each point of working device. Lubricate the grease to grease nipple in accordance with lubrication intervals. Description Fork adjustment cylinder pin Fork shaft Tilt cylinder pin Load chain Mast support pin Chain sheave pin Shorten lubricating interval when working in the water or dusty place.

  • Page 186: Electrical System

    8. ELECTRICAL SYSTEM WIRING, GAUGES C h e c k r e g u l a r l y a n d r e p a i r l o o s e o r malfunctioning gauges when found. Loose Open 160D7MI56 WELDING REPAIR...

  • Page 187: Air Conditioner And Heater

    9. AIR CONDITIONER AND HEATER CLEANING AND REPLACING FILTER Always stop the engine before servicing. Open the door, loosen the wing bolt and remove the recircular plenum assembly. Cover Filter 50D9MI58 Clean the recircular plenum using a pressurized air (Below 2 kgf/cm , 28 psi).
  • Page 188 REFRIGERANT Equipment contains fluorinated greenhouse gas. Model Type Quantity 50/60/70/80D-9 HFC-134a 0.55 kg (1.21 lb) 787 CO Global warming potential (GWP) is a measure of how much heat a gas traps in the atmosphere relative to that of carbon dioxide (CO2). GWP is calculated in terms of the 100-year warming potential of 1 of a greenhouse gas relative to 1 of CO2.

  • Page 189: Replacement And Check

    10. REPLACEMENT AND CHECK 10. REPLACEMENT AND CHECK 1) 1) WIRING, GAUGES WIRING, GAUGES Check regularly and repair the loose or malfunc- tioning gauges when found. 13036MI29 2) 2) BATTERY BATTERY Clean Clean (1) (1) ① Wash the terminal with hot water if it is contaminated, and apply grease to the terminals after washing.
  • Page 190 Prior to reinstall the cable, inspect in detail and Prior to reinstall the cable, inspect in detail and Remove (-) lead first confirm the condition of the cables and replace confirm the condition of the cables and replace it when the cables possess any kind of it when the cables possess any kind of Pos(+) abnormal damages such as cracking and wear...
  • Page 191 COOLING SYSTEM Radiator fins cleaning Remove dust between the radiator fins with compressed air. The steam or water may be used instead of compressed air. Air pressure should be less than 2 kgf/cm kPa (30 psi). The nozzle of the cleaning device should be held about 50 mm (2 in) from the radiator fins. Also, check the rubber hose connected to the radiator.
  • Page 192 For details of procedures, contact your HYUNDAI dealer. Wear safety glasses and a face shield when using compressed air. Block the tire at the opposite corner from the tire to be replaced.
  • Page 193 FUSES REPLACEMENT HORN/ STOP RMCU/ CLUSTER/ ROOM TCU B+ MODULE LINE AIRCON COVER P/N : 2DFQ-10300 CAB TILT LAMP MONITOR SENSOR LAMP HEATER HEATER REAR TAIL/ TURN/ CLUSTER/ FUEL HEAD WIPER MCU/ ECM IG TCU IG WORK BEACON BACK UP RADIO HEATER LAMP...
  • Page 194 LAMP BULBS REPLACEMENT Lamp Spec (24V) Head lamp Turn signal lamp Clearance lamp Stop lamp Backup lamp License lamp (option) Beacon lamp (option) Strobe type 50D9OM69 Rear work lamp After checking that the fuse is not blown and that there is no disconnection in the wiring harness, replace the lamp bulb.
  • Page 195 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.
  • Page 196 Steering system 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.
  • Page 197 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). EXPLOSIVE GASES : Do not smoke or have open flames or sparks near the batteries. An explosion can cause injury or death.
  • Page 198 OIL PERFORMANCE DESIGNATION: To help achieve proper engine performance and durability, use only engine lubricating oils of the proper quality. For the diesel engines, HYUNDAI recommends that you use motor oil that meets API service classification API CJ-4 or better (SAE 15W-40) for the diesel engines.
  • Page 199 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 support bushings. Lift chains Lubricate the entire length of the mast rail lift and carriage chains with HYUNDAI chain and cable lube. AIR CLEANING Always maintain a lift truck in a clean condition.
  • Page 200 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.
  • Page 201 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.

  • Page 202: Handling Truck In Extremely Hot Places

    11. HANDLING TRUCK IN EXTREMELY HOT PLACES Pay careful attention particularly to the following Radiator points when handling the truck in extremely hot places. Scale and rust form more easily in the cooling Compressed air gun system, so wash with anticorrosion liquid. Always try to have clean and soft water circulating in the system.

  • Page 203: Cold Weather Operation

    12. COLD WEATHER OPERATION PREPARATION FOR LOW TEMPERATURE Replace lubrication oil with oil of the prescribed Min ambient temperature -5 -10 -15 -20 -25 -30 -50 viscosity. (˚C ) Fuel of low pour point must be used. ASTM Amount of D975 No.1 diesel fuel should be used at 25 30 35 40 45 50 60 antifreeze (%)

  • Page 204: Recommendation Table For Lubricants

    SAE 10W-30/15W-40 (API CJ-4 class or better) T/M oil Shell DONAX TD Axle oil Shell DONAX TD Hydraulic oil ISO VG46/VG68, Hyundai genuine long life hydraulic oil ISO VG15, Conventional hydraulic oil Grease Lithium base grease NLGI No.2 Fuel ASTM D975-No.2...

  • Page 205: Fuel And Lubricants

    14. FUEL AND LUBRICANTS Ambient temperature C ( F) Capacity Service point Kind of fluid (U.S. gal) (-58) (-22) (-4) (14) (32) (50) (68) (86) (104) SAE 5W-40 SAE 30 Engine oil SAE 10W Engine oil (3.2) SAE 10W-30 SAE 15W-40 Torque Transmission converter...

  • Page 206: Specifications

    8. SPECIFICATIONS 8. SPECIFICATIONS 1. SPECIFICATION TABLE 1. SPECIFICATION TABLE 50D9SP011 Model Unit 50D-9 60D-9 70D-9 80D-9 Capacity kg (lb) 5000 (11000) 6000 (13500) 7000 (15500) 8000 (17600) ← ← ← Load center mm (in) 600 (24") Weight(Unloaded) kg (lb)

  • Page 207: Specification For Major Components

    2. SPECIFICATION FOR MAJOR COMPONENTS 50/60/70D-9 Engine Item Unit Specification Model Cummins QSF3.8 Type Vertical, water-cooled, 4-cycle DI, Tier 4 final diesel engine Cooling method Water cooling Number of cylinders and arrangement 4-cylinders, In-line Firing order 1-3-4-2 Combustion chamber type Direct injection Cylinder bore ×...
  • Page 208 (4) (4) Steering unit Steering unit Item Unit Specification Type Load sensing/Non load reaction/Dynamic signal Capacity cc/rev Rated flow 22.7 Relief pressure kgf/cm (5) (5) Power train deviced Power train deviced Item Specification Model ZF 3WG94 Torque converter Type 3 Element, 1 stage, 2 phases Stall ratio 2.395 : 1 Type...
  • Page 209 80D-9 Engine Item Unit Specification Model Cummins QSF3.8 Type Vertical, water-cooled, 4-cycle DI, Tier 4 final diesel engine Cooling method Water cooling Number of cylinders and arrangement 4-cylinders, In-line Firing order 1-3-4-2 Combustion chamber type Direct injection Cylinder bore × stroke mm (in) 102 115 mm (4.0"...
  • Page 210 Steering unit Item Unit Specification Type Load sensing/Non load reaction/Dynamic signal Capacity cc/rev Rated flow Relief pressure kgf/cm Power train deviced Item Specification Model ZF 3WG94 Torque converter Type 3 Element, 1 stage, 2 phases Stall ratio 2.395 : 1 Type Full auto, power shift Gear shift (FR/RR)

  • Page 211: Tightening Torque

    3. TIGHTENING TORQUE 3. TIGHTENING TORQUE Item Size kgf·m lbf·ft Engine mounting bolt, nut M12×1.25 12.3±3.0 89±21.7 Engine Engine bracket mounting bolt M10×1.5 6.9±1.4 50±10.1 Radiator mounting bolt, nut M10×1.5 6.9±1.4 50±10.1 Hydraulic pump mounting bolt M16×2.0 29.7±4.5 215±32.3 Hydraulic MCV mounting bolt, nut M12×1.75 12.8±3.0...

  • Page 212: Troubleshooting

    9 . TROUBLESHOOTING 9 . TROUBLESHOOTING 1. ENGINE SYSTEM 1. ENGINE SYSTEM Trouble symptom Probable cause Remedy ·Low oil level in oil pan. ·Add oil. Oil pressure warning lamp ·Oil filter element clogged. ·Replace element. fails to go out. ·Loose or worn oil pipe joint leaks oil. ·Check and repair.

  • Page 213: Electrical System

    2. ELECTRICAL SYSTEM 2. ELECTRICAL SYSTEM Trouble symptom Probable cause Remedy ·Faulty wiring. ·Check for loose terminal and discon- Lamps dimming even at maxi- mum engine speed. nected wire. ·Improper belt tension. ·Adjust belt tension. Lamps flicker during engine operation. ·Charge lamp defective.

  • Page 214: Torque Flow System

    3. TORQUE FLOW SYSTEM 3. TORQUE FLOW SYSTEM Trouble symptom Probable cause Remedy 1. Excessive oil ·Improper oil level. ·Check oil level. Add or drain oil as temperature rise 1) Torque converter necessary. ·Impeller interfering with surroundings. ·After draining oil from oil tank and transmission, check and replace interfering parts.
  • Page 215 Trouble symptom Probable cause Remedy 3.Low output power ·Insufficient hydraulic pressure : 1) Torque converter - Low oil level. - Check oil level and add oil - Air sucked in. - Check joints and pipes. If necessary, retighten joint or repla- ce packing.
  • Page 216 Trouble symptom Probable cause Remedy 4.Unusual oil pressure ·Control valve malfunctioning. 1) Oil pressure is high (1)Check for spool operation. If necessary, replace valve. (2)Check for clogging of small hole in valve body. If necessary, clean or repair. ·Cold weather. (high oil viscosity) ·When atmospheric temp is below fr- eezing point (when normal oil pressure is recover-...
  • Page 217 Trouble symptom Probable cause Remedy ·Foreign matter intruding into oil pass- ·Disassemble, check and repair or 5. Power is not transmitted (Continue) age to clutch. replace. ·Shaft spline worn. ·Disassemble, check and replace. ·Oil leaks from oil seal. ·Disassemble and check for wear of 6.

  • Page 218: Steering System

    4. STEERING SYSTEM 4. STEERING SYSTEM Trouble symptom Probable cause Remedy ·Low oil pressure. ·Check locknut. Repair. 1. Steering wheel drags. ·Bearing faulty. ·Clean or replace. ·Spring spool faulty. ·Clean or replace. ·Reaction plunger faulty. ·Replace. ·Ball-and-screw assembly faulty. ·Clean or replace. ·Sector shaft adjusting screw excessi- ·Adjust.

  • Page 219: Brake System

    5. BRAKE SYSTEM 5. BRAKE SYSTEM Trouble symptom Probable cause Remedy ·Hydraulic system leaks oil. ·Repair and add oil. 1. Insufficient braking force ·Hydraulic system sucks air. ·Bleed air. ·Disk worn. ·Replace ·Brake valve malfunctioning ·Repair or replace. ·Hydraulic system clogged ·Clean.

  • Page 220: Hydraulic System

    6. HYDRAULIC SYSTEM 6. HYDRAULIC SYSTEM Trouble symptom Probable cause Remedy ·Seal inside control valve defective. ·Replace spool or valve body. 1. Large fork lowering speed. ·Oil leaks from joint or hose. ·Replace. ·Seal inside cylinder defective. ·Replace packing. ·Tilting backward : Check valve defec- ·Clean or replace.

  • Page 221: Mast And Fork

    7. MAST AND FORK 7. MAST AND FORK 1) 1) MAST MAST Problem Problem Cause Cause Remedy Remedy ·Deformed mast or carriage. ·Disassemble, repair or replace. Forks fail to lower. ·Faulty hydraulic equipment. ·See troubleshooting hydraulic pump Fork fails to elevate and cylinders in section 6, hydraulic system.
  • Page 222 2) 2) FORKS FORKS Problem Problem Cause Cause Remedy Remedy Abrasion Long-time operations causes the fork to If the measured value is below the wear and reduces the thickness of the wear limit, replace fork. fork. Inspection for thickness is needed. ·Wear limit : Must be 90% of fork thickness Distortion...

  • Page 223: Testing And Adjusting

    10. TESTING AND ADJUSTING 10. TESTING AND ADJUSTING 1. ENGINE SYSTEM 1. ENGINE SYSTEM 1) 1) EASE OF STARTING, NOISE EASE OF STARTING, NOISE Set gear shift lever at NEUTRAL. Forward Neutral Reverse 160D7OM45 Turn the parking brake switch ON. Turn ON start switch, automatically heat- ing operated.
  • Page 224 The fuel filter cartridge cannot be inspected from the outside, so replace it periodically (refer to 7. PLANNED MAINTENANCE AND LUBRICATION). 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.
  • Page 225 8) 8) CHECK FAN BELT TENSION CHECK FAN BELT TENSION An deflection method can be used to check belt tension by applying 11 kgf (25 lbf) force between the pulleys on V-belts. If the deflection is more than one belt thickness per foot of pulley center distance, the belt tension must be adjusted.

  • Page 226: Drive System

    2. DRIVE SYSTEM 2. DRIVE SYSTEM 1) 1) GEAR SHIFT LEVER GEAR SHIFT LEVER (1) (1) Neutral starting Neutral starting Engine can be started only when the shifting lever is in neutral position. (2) (2) Shifting FWD/REV lever Shifting FWD/REV lever ①...
  • Page 227 (3) (3) Inching pedal Inching pedal ·Adjust stopper bolt (1) so that pedal angle is "H". ± - Pedal angle (H) : 35。 1。 ·Adjust bolt (2) so that brake pedal interconnects with inching pedal at inching pedal stroke, 20~24 mm (0.8~0.9 in).

  • Page 228: Travel System

    3. TRAVEL SYSTEM 3. TRAVEL SYSTEM TIRES TIRES Check tire pressure using tire gauge : SEE page 5-3 CHECK BEFORE STARTING ENGINE. Check visually for cracks and damage to tread and side wall. If crack or damage is serious, replace tire. Wear Measure tread of pneumatic tires(tires with air).

  • Page 229: Steering System

    4. STEERING SYSTEM 4. STEERING SYSTEM STEERING WHEEL STEERING WHEEL 30~60mm Set rear wheels facing straight forward, (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 ~ 60 mm at rim of steering wheel.

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