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Hyundai 50D-9, Manual, Page: 227 / 229

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Hyundai 50D-9 Manual Download Page 227

10-5

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).

(3)

(3)

(1)

(2)

22mm

H

50D7ATA05

Summary of Contents for 50D-9

Page 1: ...ns 1 6 6 Operator protection 1 7 7 Fork safety 1 8 8 Pinch points 1 9 9 Travel 1 10 10 Grades ramps slopes and inclines 1 11 11 Tip over 1 12 12 Surface and capacity 1 14 13 Parking 1 15 14 Refueling 1 16 15 Step 1 17 16 Operator s safety rules 1 18 17 Side shift 1 19 2 OPERATING HAZARDS 2 OPERATING HAZARDS 1 Loose loads 2 1 2 Long and wide loads 2 2 3 Rear swing 2 2 4 Low overhead clearance 2 3 5...

Page 2: ...1 2 Suggestion for new truck 4 3 3 Fuel safety practices 4 4 5 STARTING AND OPERATING PROCEDURES 5 STARTING AND OPERATING PROCEDURES 1 Before operating the truck 5 1 2 Check before operation 5 2 3 Check before starting engine 5 3 4 Seat adjustment 5 8 5 Starting from a safe condition 5 9 6 General starting and operating tips 5 10 7 Starting and stopping the engine 5 11 8 Warming up operation 5 15 ...

Page 3: ...Air conditioner and heater 7 46 10 Replacement and check 7 47 11 Handling truck in extremely hot places 7 60 12 Cold weather operation 7 61 13 Recommendation table for lubricants 7 62 14 Fuel and lubricants 7 63 8 SPECIFICATIONS 8 SPECIFICATIONS 1 Specification table 8 1 2 Specification for major components 8 2 3 Tightening torque 8 6 9 TROUBLESHOOTING 9 TROUBLESHOOTING 1 Engine system 9 1 2 Elect...

Page 4: ...ork 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 be...

Page 5: ...tial 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 Operator Daily Inspection Safety and Operating Checks A lift truck should always be examined by the operator before driving to be sure it...

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

Page 7: ...ies 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 y...

Page 8: ...53 are as followings EC REGULATION APPROVED EC REGULATION APPROVED Model 50 60 70D 9 80D 9 LPA 80 dB 78 6 dB LWA EU only 106 dB 107 2 dB The value of vibrations transmitted by the operator s seat are lower than standard value of 2005 88 EC ...

Page 9: ...Blue 25 Engine room 26 Safety instruction OPSS 27 Fire extinguisher 28 Hammer 29 Accumulator 30 Safety work 41 Name plate UL or CE 42 Label UL 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 7 12 6 16 3 4 1 1 4 FAN SHROUD RCV LEVER DASHBOARD COVER 13 14 2 2 4 4 8 10 9 SECTION A A SECTION B B B B A A 11 30 30 20 20 ...

Page 10: ...s positioned on the top side of the counterweight near the silencer Coolant must be checked as specified in Coolant must be checked as specified in the maintenance chart the maintenance chart 2 2 25L7A0OM10 25L7A0OM06 RADIATOR CAP FAN RADIATOR CAP FAN item 6 This warning label is positioned on the cooling fan shroud of the radiator to warn of the danger or injury from spinning fan blades and forbi...

Page 11: ... of your body is put between moving parts of the mast between moving parts of the mast 4 4 35DEOM103 TIRE PRESSURE TIRE PRESSURE Item 20 This label is positioned on the front and rear left fender Tire pressure must be checked in Tire pressure must be checked in accordance with the maintenance chart accordance with the maintenance chart Refer to page 5 3 for the regulated tire Refer to page 5 3 for...

Page 12: ...be possible only if the operator is in the normal operating position Transmission will automatically shift to neutral upon the exiting of the operator The forward reverse lever must be cycled through neutral with the operator in the normal operating position to regain powered direction control Control of mast tilting lifting and lowering is not possible through operation of the appropriate control...

Page 13: ...is filled with high pressure nitrogen gas and it is pressure nitrogen gas and it is extremely dangerous if it is handled in extremely dangerous if it is handled in the wrong way Always observe the the wrong way Always observe the following precautions following precautions Never make any hole in the accumulator Never make any hole in the accumulator expose it to flame or fire expose it to flame or...

Page 14: ...the operator have severe injury or death in the event of a tip over Outstretch the legs as widely as possible and grasp firmly the steering handle Learn the body to the opposite direction in order to avoid severe injury or death when the truck is tipped over Refer to page 3 3 for details Refer to page 3 3 for details 1 2 3 4 5 6 7 25L7A0OM09 1 12 12 NOISE NOISE Item 23 This label is located on the...

Page 15: ...er Read and understand the instructions Read and understand the instructions adhered decal on the fire extinguisher adhered decal on the fire extinguisher HAMER HAMER Item 28 This label is positioned on the inside of left side door The rear window serves as an alternate The rear window serves as an alternate exit exit To remove rear window pull the ring and To remove rear window pull the ring and ...

Page 16: ...NUMBER It s shown on front of the right side frame 1 1 50D7ASM02 ENGINE SERIAL NUMBER ENGINE SERIAL NUMBER The numbers are located on the engine name plate 2 2 Important safety hint Important safety hint It indicates matters which can cause the great loss on the truck or the surroundings It indicates matters which can cause the great loss on the truck or the surroundings It indicates the useful in...

Page 17: ...brication 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 50D9OM02 1 SAFETY HINTS 1 SAFETY HINTS 1 DAILY INSPECTION 1 DAILY INSPECTION ...

Page 18: ... wear safety equipment when required D35AOM05 Don t mix drugs or alcohol with your job Don t block safety or emergency equipment 50D9OM04 D35AOM02 Don t smoke in NO SMOKING areas or when refueling D35AOM06 2 DO S AND DON TS 2 DO S AND DON TS ...

Page 19: ...rs 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: ...ELTS 3 SEAT BELTS Seat belts can reduce injuries Seat belts can reduce injuries 22D9TOM10 Always buckle up for the truck equipped Always buckle up for the truck equipped with safety belt with safety belt 22D9TOM09 ...

Page 21: ...1 5 50D9OM12 50D9OM14 4 NO RIDERS 4 NO RIDERS The operator is the only one who should be on a truck Never transport personnel on the forks of a lift truck 1 2 ...

Page 22: ...oadway 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 People may not watch for you D35AOM14 Watch for people standing back even when you are parked 50D9OM06 5 PEDESTRIANS 5 PEDESTRIANS 1 2 3 ...

Page 23: ... 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 use of it 1 2 ...

Page 24: ...orks 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 50D9OM17 7 FORK SAFETY 7 FORK SAFETY ...

Page 25: ...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 Always chain or attachment by yourself Always get a trained mechanic get a trained mechanic 50D9OM63 8 PINCH POINTS 8 PINCH POINTS ...

Page 26: ...on 50D9OM18 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 50D9OM25 Unstable loads are a hazard to you and to your fellow workers Always make certain that the load is well stacked and evenly positioned across both forks Never attempt to lift a load with only one fork Wrong 50D9OM26 9 TR...

Page 27: ...S SLOPES AND INCLINES 10 GRADES RAMPS SLOPES AND INCLINES 50D9OM30 50D9OM33 Unloaded Forks downgrade Loaded Forks upgrade 1 2 Never turn on a grade either loaded or unloaded Never turn on a grade either loaded or unloaded ...

Page 28: ...ongitudinal tip over can occur by driving with the load down slope on a steep grade Lateral and longitudinal tip over can occur if the truck is driven over objects on the floor or ground off the edge 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 dr...

Page 29: ... as illustrated right Brace yourself as illustrated right 1 Make sure your seat belt is fastened securely if the truck is equipped with seat belt 2 Stay in your seat 3 Grip the wheel 4 Brace your feet Your chances for survival in a tip over Your chances for survival in a tip over are better if you stay with the truck in are better if you stay with the truck in your seat your seat 3 1 2 4 ...

Page 30: ...ey 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 the capacity of the elevator you intend to use Do not overload use Do not overload 12 SURFACE AND CAPACITY 12 SURFACE AND CAPACITY ...

Page 31: ...ore leaving the truck Be sure the travel control is in NEUTRAL 50D9OM42 Lower forks fully to floor and tilt forward ON OFF START 1 2 50D9OM44 Set the parking brake Position 1 OFF Release Position 2 ON Lock Turn key to OFF position 13 PARKING 13 PARKING 1 2 3 4 5 50D9OM37 ...

Page 32: ...oil check around the truck for oil leakage 50D9OM47 Keep away from fire when adding oil or during operation DIESEL 50D7AOM48 After adding oil wipe off any oil spilled on the truck 50D9OM49 14 REFUELING 14 REFUELING 1 2 3 ...

Page 33: ...1 17 When getting on or off the truck use the step provided 50D9OM50 Do not jump up or down from the truck 50D9OM52 15 STEP 15 STEP 1 2 ...

Page 34: ...brake warning This function works when the key switch is not only ON or START position but also OFF position Alarm sounds in 2 seconds from the driver s off the seat with the parking brake released To release the function the parking brake switch must be turned to ON PARK position When the key switch is OFF position alarm will sound only for 30 seconds 1 18 All operational functions require that t...

Page 35: ...duce the stability of the truck and may cause over turning Avoid overloading or uneven loading Avoid overloading or uneven loading Load on the forks according to load capacity mentioned on the truck name plate when sideshift is applied Uneven loading will deteriorate the stability of the truck when the load is raised Top of the load should not extend above Top of the load should not extend above t...

Page 36: ...ns Never carry loose or uneven material 50D9OM53 Center wide loads 50D9OM55 Stack and band loose material D35AOM41 Avoid sudden braking or starting When the truck is loaded do not drive at When the truck is loaded do not drive at maximum speed maximum speed 50D9OM56 2 OPERATING HAZARDS 2 OPERATING HAZARDS 1 LOOSE LOADS 1 LOOSE LOADS ...

Page 37: ...g A long load reduces the capacity of the A long load reduces the capacity of the truck Know and understand your truck truck Know and understand your truck load rating load rating 50D9OM57 When turning be sure the rear end of When turning be sure the rear end of the truck does not swing into racks the truck does not swing into racks posts etc Watch for pedestrians beside posts etc Watch for pedest...

Page 38: ...truck over or spill a load truck over or spill a load 50D9OM74 Slow down before turning Slow down before turning The truck can tip over The truck can tip over 50D9OM46 Turn too sharp with a raised load and Turn too sharp with a raised load and your truck can tip even at slow speeds your truck can tip even at slow speeds Travel with a load raised only when Travel with a load raised only when removi...

Page 39: ...Slack chains mean rail or carriage hang Slack chains mean rail or carriage hang up up Raise the forks before you move or Raise the forks before you move or broken chains can result broken chains can result In case forks with loads are stuck while In case forks with loads are stuck while lowering the mast lift the mast again and lowering the mast lift the mast again and prevent chains from being sl...

Page 40: ...ng near the electrical lines is The operating near the electrical lines is very dangerous very dangerous Operate within safe working permitted as Operate within safe working permitted as below below 9 CAUTION FOR ELECTRICAL LINES 9 CAUTION FOR ELECTRICAL LINES 50D9OM76 50D9OM77 If the truck touches the electric power If the truck touches the electric power lines keep sitting on the operator s seat...

Page 41: ...equipped with supports such as a load table for the load Never travel the forklift while the side shift is moved with load In case of moving the side shift with load it can be caused load dropping or overturning of the forklift due to unbalanced weight The forklift can be overturned due to the The forklift can be overturned due to the unbalanced load unbalanced load 50D9OM71 11 SIDE SHIFT 11 SIDE ...

Page 42: ...ove the load to push or pull of it by the side shift It can be caused damaging of the loads or injuring of the people 50D9OM72 While traveling the forklift with the load on the side shift if the operator lift or lower the load without shifting it in the netural position it can be overturned the forklift due to unstabled load When lifting or lowering the side shift with load it should be observed t...

Page 43: ... 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 It can be caused to drop the load It can be caused to drop the load 50D9OM75A 12 FORK POSITIONER 12 FORK POSITIONER ...

Page 44: ... Rear work lamp opt 11 Operator s seat 12 Bonnet 13 Counterweight 14 Rear wheel 15 Front wheel 16 Rear combination lamp 17 Beacon lamp opt 18 Camera opt 19 Silencer 20 Pre cleaner 21 Air conditioner opt 22 Rear view mirror 4 6 1 2 3 15 5 12 13 11 7 14 9 8 16 10 21 18 17 20 19 22 50D9OM54 3 KNOW YOUR TRUCK 1 GENERAL LOCATIONS ...

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

Page 46: ...ll 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 quick...

Page 47: ...Accelerator pedal Brake pedal Handsfree opt Remote controller opt Operator seat 12V socket 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 tr...

Page 48: ...f the truck  Warning lamps Indicate abnormality of the truck  Pilot lamps Indicate operating status of the truck  LCD Display the truck model error code and engine speed etc  Buttons Select the truck model error code and engine speed etc and stop the buzzer sound ö The cluster installed on this truck does not entirely guarantee the condition of the truck Daily inspection should be performed ac...

Page 49: ...d until the indicator is in the operating range If the indicator is in the red range turn OFF the engine and check the radiator and engine If the gauge indicates red range even though the truck is on the normal condition check the electric device as that can be caused by the poor connection of electricity or sensor Η Θ Ι ö This range indicates the temperature of transmission oil ÂWhite range 40 10...

Page 50: ...rected Η Θ ö Brake fail warning lamp 2 50D9CD02 1 When the warning and pilot lamps occur over eight you can display next lamps by push the button 俍 ö 50D9CD904 SCR cleaning warning lamp Engine stop warning lamp Engine oil pressure warning lamp Water in fuel warning lamp Brake system pressure warning lamp Transmission error warning lamp Air cleaner warning lamp Fuel low level warning lamp Engine co...

Page 51: ... ON during engine operation Η Θ Fill the fuel immediately when the lamp is turned ON Η This lamp operates by the vacuum caused inside when the filter of air cleaner is clogged Check the filter and clean or replace it when the lamp is ON Η Θ Air cleaner warning lamp Battery charging warning lamp Fuel low level warning lamp 4 5 6 This lamp lights up when the prefilter is filled with water or malfunc...

Page 52: ...temperature 107 C 225 F ÂLamp ON Abnormal ÂLamp OFF Normal When this lamp lights up during operation stop the engine and check the truck This lamp lights ON and the information window of the LCD shows the error code when an error occur in the transmission Immediately pull the truck to a convenient stop Stop the engine Investigate the cause Consult a HYUNDAI dealer to investigate the cause Do not o...

Page 53: ...Flash On DEF level 0 Engine error code 3547 3714 50 derate 30 min DEF level final derate warning Flash On On Engine error code 3712 Contact Hyundai service center or dealer Manual SCR cleaning applies if the machine is in a fireproof area and there is no plan to turn off the machine during the SCR cleaning Stop and park the machine Push the switch to position 刯 to initiate the manual SCR cleaning ...

Page 54: ...uid into DEF tank Refer to the page 3 10 for detail 刮 侍 侍 DEF Diesel Exhaust Fluid low warning lamp 13 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 刮 侍 Engine stop warning lamp 50D9CD32 50D9CD33 14 ...

Page 55: ... 2 PILOT LAMPS 4 OPSS pilot lamp SCR cleaning inhibit pilot lamp HEST pilot lamp Preheater pilot lamp Fuel warmer pilot lamp Inching pilot lamp Expendables replacement indicator lamp Right turning pilot lamp Parking brake pilot lamp Head light pilot lamp Left turning pilot lamp 50D9CD02 2 When the warning and pilot lamps occur over eight you can display next lamps by push the button Ķ ö 50D93CD10 ...

Page 56: ...engine Refer to page 5 12 Η Θ ö Preheater pilot lamp 4 Inching pilot lamp 5 50D9CD07 50D93CD14 50D93CD65 This lamp lights ON when the fuel warmer switch is pressed Η 50D93CD43 Fuel warmer pilot lamp 6 50D9CD14 OPSS pilot lamp 7 This signal lamp lights ON when the operator leaves the seat Powered travel movement of the truck shall be possible only if the operator is in the normal operating position...

Page 57: ...ngine service It merely alerts the equipment operator to high exhaust temperatures It will be common for the lamp to illuminate on and off during normal equipment operation as the engine completes the SCR cleaning Η Θ Ι ö HEST High exhaust system temperature pilot lamp 9 50D9CL003 This pilot lamp lights ON when the SCR cleaning switch is pushed inhibit position therefore automatic and manual SCR c...

Page 58: ...p right down Move in menu left up right down Decrease Increase input value When the warning and pilot lamps occur over six you can display next lamps by push the button Ķ Η Θ Η Η Θ Ι Buzzer stop ESC button 1 Menu button Move button 2 3 CLUSTER BUTTON 4 50D9CD121 Menu button Enter button Move button Buzzer stop ESC button 50D9CD24 50D9CD23 50D9CD22 50D9CD25 Enter button This button is used to selec...

Page 59: ...screen Main screen Communication error Sub menu screen MENU Main screen when occurred communication error between the cluster and TCU MCU ECU ö 1 Engine rpm 2 Load indicator opt 3 Hour meter 4 Odometer 5 Current time 6 DEF level gauge 7 Rear wheel angle opt 8 Mast angle opt 9 Vehicle angle X opt 10 Vehicle angle Y opt 11 T M info error code gear warning 12 Temperature outdoor temp setting temp 13 ...

Page 60: ...nance management Signal statue User password change RMCU comm Display failure status engine transmission Replacement Change interval oils and filters Display information of sensors User password change 5 10 digit Orbcomm GPS antenna 6 LCD adjustment Time setting Unit setting Language setting AS phone number ESL password change Maintenance management LCD brightness setting Time setting Unit setting...

Page 61: ...ve a condition Right set rear wheel calibration Center set rear wheel calibration Left set rear wheel calibration Select the Model The initial model is selected at the factory so don t change the different model        ö Equipment Choose the equipment Model select Rear angle setting Tilt setting 3 Η Θ Κ Ι 50D9CD20 50D9CD22 50D9CD29 50D9CD26 50D9CD21 50D9CD23 50D9CD30 50D9CD27 50D9CD24 50D9C...

Page 62: ...0 cm Weight correction ON Initialization It is initialized loaded status and unloaded status    Weight sensor setting Cross section Load weight adjust Λ a b 50D9CD35 50D9CD36 50D9CD39 50D9CD39 50D9CD39 50D9CD37 50D9CD40 50D9CD44 50D9CD49 50D9CD38 50D9CD41 50D9CD45 50D9CD50 50D9CD42 50D9CD46 50D9CD51 50D9CD47 Enter the designated cross section cm2  Mast spec 50 60 70 80D 9 V mast TS mast TF mas...

Page 63: ... 50D9CD35 50D9CD35 50D9CD53 50D9CD57 50D9CD54 50D9CD58 50D9CD55 Set ON OFF function for using limitation of ignition and time for starting Set time 5 minutes for starting In 5 minutes you can restart without password but after 5 minutes you should input password for starting   ESL setting Μ 50D9CD59 50D9CD60 50D9CD61 50D9CD63 50D9CD62 50D9CD64 ...

Page 64: ... When it is finished OK sign at gear box Press Menu ECS Enter button Start the engine AEB start KEY ON Brake pedal sensor calibration Software version check for MCU Cluster RMCU Â Â Â Â Â Â Â Vehicle max speed limit AEB setting R MCU Cluster information Ν Ξ Ο 50D9CD65 50D9CD71 50D9CD73 50D9CD66 50D9CD72 50D9CD74 50D9CD67 50D9CD68 50D9CD69 50D9CD70 ...

Page 65: ... 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 Unit V ex Min 0 48 Mid 2 52 Max 4 52 Â Â ...

Page 66: ...e neutral Lever state 2 5V ex If you set up the Upper 0 26 Lower 0 24 Lever operating range will be Upper zone 2 76V 2 5 0 26 4 5V Lever Max value Lower zone 2 26V 2 5 0 24 0 5V Lever Min value  50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 ...

Page 67: ... of movements according ot the current value Unit Over 110D 9 only mA Under 80D 9 Only ex If the Max value increase the maximum speed will also increase If the Min value increase the minimum speed will also increase  50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 50D9CD74 ...

Page 68: ...ge expendable supplies Change the replacement cycle Show the Maintenance Information below 10 Delete the old item when Information have more than 10 Â Â Â Â Â Â Â Maintenance Choose the maintenance Current failure history Maintenance management 4 Η Θ Ι 50D9CD75 50D9CD81 50D9CD76 50D9CD84 50D9CD82 50D9CD85 50D9CD88 50D9CD83 50D9CD87 50D9CD86 50D9CD77 50D9CD78 50D9CD79 50D9CD80 ...

Page 69: ... 50D9CD93 You should set password by five to ten digit When successfully opened RMCU communication Except for the RMCU Comm   User password change Λ 50D9CD94 50D9CD95 50D9CD96 50D9CD97 RMCU Comm Μ 50D9CD98 50D9CD102 50D9CD106 50D9CD107 50D9CD99 50D9CD103 50D9CD101 50D9CD105 50D9CD100 50D9CD104 ...

Page 70: ... 50D9CD110 50D9CD117 50D9CD111 50D9CD113 50D9CD112 50D9CD114 50D9CD115 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 Set the time Year Month Day Hour Minute AM PM Â Â Â Â ...

Page 71: ...ur device 13 Multiple language You should set password by five to ten digit Check and change of contact information for customer service    Language setting ESL password change A S phone number Λ Ν Μ 50D9CD120 50D9CD127 50D9CD124 50D9CD121 50D9CD128 50D9CD125 50D9CD122 50D9CD119 50D9CD129 50D9CD126 50D9CD123 50D9CD130 ...

Page 72: ...3 26 Show the maintenance information replacement cycle elapsed time change count alarm information  Maintenance management Ξ 50D9CD131 50D9CD132 50D9CD133 ...

Page 73: ...formation about the selected driving range The automatic range is symbolized by arrows above and below the bar indicator In case of possible errors in the system a wrench appears on the display combined with indication of the error number Also sporadically occurring errors can be indicated 1 If it happens error codes consult with Hyundai service center to repair the fault ö 50D93ACD33 Transmission...

Page 74: ...n fault active Select neutral to get fault code displayed WT Warning torque converter temperature Changes between actual gear direction while driving in neutral only displayed if no fault is detected spanner WS Warning sump temperature Changes between actual gear direction while driving in neutral only displayed if no fault is detected spanner WE Warning high engine speed Changes between actual ge...

Page 75: ...hex 34 hex 35 hex 36 hex 37 hex 38 hex 39 hex Meaning of error code Logical error at gear range signal Logical error at direction select signal Short circuit to battery voltage at clutch cutoff input Short circuit to ground or open circuit at clutch cutoff input Short circuit to battery voltage or open circuit at temperature sensor input Short circuit to ground at temperature sensor input Short ci...

Page 76: ...ery voltage at clutch KE Short circuit to ground at clutch KE Open circuit at clutch KE Short circuit to battery voltage at clutch KV Short circuit to ground at clutch KV Open circuit at clutch KV Short circuit to battery voltage at clutch KR Short circuit to ground at clutch KR Open circuit at clutch KR Short circuit to ground at relay reverse warning alarm Short circuit to battery voltage at rel...

Page 77: ...rt circuit to battery voltage at power supply for sensors Short circuit to ground at power supply for sensors Low voltage at battery High voltage at battery Error at valve power supply 1 Error at valve power supply 2 Communication failure on devicenet General EEPROM fault Configuration lost Application error ...

Page 78: ...switch opt Hazard switch opt Switch panel Center horn Multi function switch Master switch opt Fuel warmer switch Main light switch Cover In decrement switch SCR cleaning switch Top wiper washer switch opt Start switch Cover Parking brake switch Rear wiper washer switch Engine mode switch opt 50D9CD05 ...

Page 79: ...nd the warning lamp on the cluster will comes ON When operating the gear selector lever be sure to release the parking brake If the truck is operated with the parking brake engaged the brake will overheat and may cause the brake system to go out of order 4 1 2 ö MAIN LIGHT SWITCH This switch is used to operate the head light by one steps First step Tail lamp comes ON Second step Head lamp comes ON...

Page 80: ...switch fully for the autoshift function changing from 2nd to 3rd gear shift mode 1 2 3 7 1 2 3 50D9CD49 8 Horn By pressing position Η the horn sounds and by releasing the horn stops Sound the horn to warn near by personnel before tilting the cabin Tilting of the cabin Press the cabin tilt switch in order to tilt the cabin to right side or return to original location Refer to page 7 18 for the tilt...

Page 81: ...FF ON 35D9AOM18 This switch turn ON the strobe light 1 11 10 When engine running the low rpm of engine increase or decrease by 25 rpm by operating this switch Engine low rpm returns to normal value when engine restarted This switch is used to operate the wiper and washer on the top of the cab The washer liquid is sprayed and the wiper is operated only while pressing this switch OFF ON INC DECREMEN...

Page 82: ... Ι ö MULTI FUNCTION SWITCH 16 O J Ɇ ɇ 73033CD29 Turning switch This switch is used to warn or signal the turning direction of the truck to other vehicles or equipment Push the lever up for turning left pull the lever down for turning right 2 Η Θ Left turning Right turning 73033CD31 MASTER SWITCH OPTION This switch is used to shut off the entire electrical system When the machine is not operated fo...

Page 83: ... SCR cleaning Refer to the page 3 24 for details This switch can be move to the manual SCR cleaning position Θ only when the safety button is pulled to backward Also this switch return to the OFF position when released the manual SCR cleaning position Θ 1 2 3 4 SCR Selective Catalytic Reduction CLEANING SWITCH 1 2 OFF 50D9OM21A 18 刮 刯 侍 侍 侍 刮 刯 到 REAR WIPER WASHER SWITCH This switch is used to ope...

Page 84: ...or lever Inching pedal Accelerator pedal Brake pedal Lift lever Tilt lever 3 spool lever opt 4 spool lever opt 5 spool lever opt 7 CONTROL DEVICE LIFT LEVER 1 1 2 3 50D9CD12 Tilt forward Tilt backward TILT LEVER 2 50D9CD16 50D9CD08 ö TILT FORWARD PUSH the lever FORWARD to tilt mast FORWARD TILT BACKWARD PULL the lever BACK to tilt mast BACKWARD HOLDING When the lever is released tilting action sto...

Page 85: ...RK POSITIONER FORK POSITIONER SYNCHRONIZER TYPE 4 Η Θ 50D9CD19 LH MOVEMENT Push the lever forward to move the left hand for the side shift RH MOVEMENT Pull the lever backward to move the right hand for the side shift 1 2 LEVER FOR SIDE SHIFT 3 LH RH 50D9CD17 1 LH FORK MOVEMENT Push the lever forward to move outward for the LH fork Pull the lever backward to move inward for the LH fork Outward Inwa...

Page 86: ...le will operate the steering function Turning the steering wheel left the truck moves to the left side and turning it right the truck moves to the right side Left Right STEERING WHEEL 6 1 2 73033CD33 This lever is used for gear selection forward 3 stages and reverse 3 stages If you push the gear selector lever the truck moves forward but pulling the gear selector lever the truck moves backward If ...

Page 87: ...lifting up or putting down loads Do not put your foot on the inching pedal or brake pedal unless using it 1 INCHING PEDAL 9 160D7ECD34 ö By pulling down the lever the wheel is adjustable to tilt By pulling up the lever the wheel is adjustable to telescope Adjustable steering wheel Accommodates various operator s conditions Tilting abgle 40 Telescopic stroke 80 mm Pull the handle attached on the bo...

Page 88: ... pleasant operation against outside temperature and defrost on window glass 8 AIR CONDITIONER AND HEATER 50D9CD90 AIR CONDITIONER BUTTON When you push this button air conditioner system is operated Determines whether to perform a cooling function of air conditioner Η Pilot lamp ON Air conditioner operation Θ Pilot lamp OFF Fan only The AUTO pilot lamp ON when this button is pushed 1 2 ö 50D9CD50 1...

Page 89: ...p OFF The air circulates in the cab The pilot lamp is turned ON when the button is pushed Check out the fresh air filter periodically to keep a good efficiency Change air occasionally when using recirculation for a long time Check out the recirculation filter periodically to keep a good efficiency AIR INLET CONTROL BUTTON 50D9CD52 Fan speed is controlled automatically by set temperature The AUTO p...

Page 90: ...ervice socket Use cigar lighter socket when you need emergency power Do not use the lighter exceeding 24 V 100 W Utilize the power of 12 V as your need and do not exceed power of 12 V 120 W 24V 1 2 1 2 ö 1 73033CD49 R5573CD49 3 44 Rear Front Radio and USB player option Monitor option Cigar lighter Handsfree option Remote controller option 12V socket 9 OTHERS 50D9CD09 ...

Page 91: ...ocket USB Ear HP Indicator lamp Service socket USB Ear HP Mobile phone storage box 21093CD51 21093CD51A 1 Mobile phone can be stored when call by handsfree 刮 HANDSFREE OPTION 4 This socket is used to charging the mobile phone USB socket 刮 2 This can be used protect you privacy calling by using ear phone The mobile phone must be connected handsfree jack socket Private call jack socket 刮 刯 3 USB Ear...

Page 92: ...nect 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 刮 刯 到 This lamp is turned ON when the handsfree mode selected Indicator lamp 刮 5 USB Ear HP 21093CD51E ...

Page 93: ... HYUNDAI and set connect with Bluetooth on the mobile phone Default password 0000 The Bluetooth pairing is made the LCD screen shows CONNECTED Once the Bluetooth pairing is made they will be automatically connected after 20 seconds when start key ON When you want to deactivate the pairing press and hold the button for more than 3 seconds then you can hear beep sounds twice and the function will be...

Page 94: ...free ON or OFF This switch is turned to right the handsfree volume is increased over 7 steps If it is turned to left volume will be decreased This switch adjust the audio volume when selected audio mode Power and volume switch Η Θ Ι ö 1 This button is to select the handsfree mode or audio mode ÂLamp ON Handsfree mode TEL MUTE displayed ON audio LCD ÂLamp OFF Audio mode Mode change button Η 2 This ...

Page 95: ...ation of higher frequency and the next song of the MP3 Turn a station of lower frequency and the previous song of the MP3 Η Θ Mute button Short press this button to mute or cancel the mute silence while broadcasting Η 6 Mode button 7 Press the mode button to select the desired mode Radio Ą MP3 Ą AUX The LCD displayed each mode Η Θ ö This MIC transfers user voice to receiver of the call when making...

Page 96: ...o handsfree You can make a call to external worker without holding the radio by hand The radio is not installed to the machine Η Θ Ι ö 55I3CD31H Talk button The call is connected while pressing this button when TALK button is activated Unlike mobile phones when you want to talk through the radio you need to press the button Push to talk method While one is talking through the radio the other party...

Page 97: ...wards up to 7 swivels left and right up to 15 6 50D9CD211 No Symbol Name Description 1 俋 LEFT Move the Menu left Lower the value 2 侐 MENU ENTER Enter the OSD menu Choose the menu 3 俍 RIGHT Move the Menu right Upper the value Sunshade LCD 7 OSD Buttons ...

Page 98: ...0D9CD204K Display one camera image on screen Press left or right key to change the camera channel Display two camera images on screen Press left or right key to change the camera channel Display four camera images on screen      Rear Front Side 1 Side 2 Rear Front Rear Side 1 Rear Side 2 Front Side 2 Front Side 1 Front Rear Rear Front Side 1 Side 2 ...

Page 99: ...ting Language 2 3 4 50D9CD205 50D9CD207 50D9CD209 50D9CD206 50D9CD208 50D9CD210 Depending on the gear state forward backward camera channel is switched automatically Adjust the display brightness Set the language 13 multiple language 余 余 余 ...

Page 100: ...draulic oil may be hot or under pressure When inspecting a lift truck wear safety Leaking hydraulic oil may be hot or under pressure When inspecting a lift truck wear safety glasses and do not check for leaks with bare hands glasses and do not check for leaks with bare hands VISUAL CHECKS VISUAL CHECKS First perform a visual inspection of the truck and its major components Walk around your lift tr...

Page 101: ... meters and indicator lights Service brakes inching pedal and parking brakes Hydraulic controls lift tilt and auxiliary If installed Accelerator Directional control Steering system Lift mechanism and any attachments When the functional check are completed follow the standard shutdown procedures standard shutdown procedures given in Section 5 Starting and operating procedures Starting and operating...

Page 102: ...fuel Check regularly the lubrication and fill Grease daily all lubrication points Tighten bolts Warm up the truck fully before operation Check the gauges during operation Check if the truck is operating normally during operation Replace following after initial hours of operation Replace following after initial hours of operation 4 4 Avoid excessive operation for initial 100 hours 2 SUGGESTION FOR ...

Page 103: ...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 safe distance while refueling 100D7OM106 D35AOM106 CLEAN UP SPILLS D35AOM106 USE CLEAN PROPERLY MARKED FUEL CANS D35AOM106 DANGER DIESEL FLAMMABLE ...

Page 104: ...r lift truck before operating at the start of each shift Before putting your truck to Inspect your lift truck before operating at the start of each shift Before putting your truck to use check the operation of the controls and all systems 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 Protect yo...

Page 105: ...ur personal safety and to realize maximum service life for your truck The numbers on the inspection chart show the order of inspection These numbers correspond to the check item numbers given on the next pages Hang a caution sign on the truck for example Do not start Do not start or Maintenance in progress Maintenance in progress This will prevent anyone from starting or moving the truck by mistak...

Page 106: ...erious injury or damage The tires and rims should always be serviced or changed by trained personnel damage The tires and rims should always be serviced or changed by trained personnel using the correct tools and procedures For details of procedures contact your HYUNDAI using the correct tools and procedures For details of procedures contact your HYUNDAI dealer or tire repair shop dealer or tire r...

Page 107: ...tor to cool down before adding water Alway allow the radiator to cool down before adding water At the operating temperature the engine cooling water is at high temperature and pressure At the operating temperature the engine cooling water is at high temperature and pressure so it is dangerous to try to open the radiator cap Wait until the radiator is cool enough to be so it is dangerous to try to ...

Page 108: ... OK NOT OK 120096MA42 120096MA43 2609A6MA47 NOT OK INSPECTION OF COOLING FAN INSPECTION OF COOLING FAN Personal injury can result from a fan blade fail Personal injury can result from a fan blade fail ure Never pull or pry on the fan This can ure Never pull or pry on the fan This can damage the fan blade and cause fan failure damage the fan blade and cause fan failure Rotate the crankshaft by usin...

Page 109: ...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 and always keep the safety rules 50D9OM36 CHECK HYDRAULIC OIL LEVEL CHECK HYDRAULIC OIL LEVEL 8 8 Rest fork on ground and stop engine Check the oil level from the level gauge of hydraulic oil tank 1 2 ...

Page 110: ...OW add the washer liquid In cold winter days or water The capacity of the tank is 1 liter days or water The capacity of the tank is 1 liter 1 1 MULTI FUNCTION SWITCH MULTI FUNCTION SWITCH O J Ⅰ Ⅱ 73033CD29 Turning switch Turning switch This switch is used to warn or signal the turning direction of the truck to other vehicles or equipment Push the lever up for turning left pull the lever down for t...

Page 111: ...ard Backward adjustment A Forward Backward adjustment A Pull lever A to adjust seat forward or back ward Reclining adjustment B Reclining adjustment B Pull lever B to adjustment seat back rest Weight adjustment C Weight adjustment C Lumbar adjustment D Lumbar adjustment D Turn line knob D to adjust lumbar support up and down Heated seat switch option Heated seat switch option Press this switch in ...

Page 112: ...ontrols function All controls are in neutral or other correct position The truck has received its daily inspection and ready and safe to operate Put the 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 Forks are down Set the parking brake 50D9OM31 Forward Neutral Reverse 160D7OM45 5 STAR...

Page 113: ...ife 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 u...

Page 114: ...s remain ON 1 2 3 7 STARTING AND STOPPING THE ENGINE 7 STARTING AND STOPPING THE ENGINE 1 1 1 3 2 Gear selector lever Parking brake switch 50D9OP03 STARTING ENGINE IN NORMAL TEMPER STARTING ENGINE IN NORMAL TEMPER ATURE ATURE Sound the horn to warn the surroundings after Sound the horn to warn the surroundings after checking if personnel or obstacles are in the checking if personnel or obstacles a...

Page 115: ...he indicator of transmission oil temperature gauge 2 in the operating range Is the engine sound and the color of exhaust gas normal Are the sound and vibration normal 1 2 4 4 1 2 3 4 50D9OP06 When the preheater warning lamp is turned ON the preheating function is actuated within When the preheater warning lamp is turned ON the preheating function is actuated within 10 45 seconds in accordance with...

Page 116: ...g produces explosive 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 fumes The truck should be refueled only at the specified refueling point Stop the engine and get off the truck when refueling Stop the engine and get off the truck when refueling If the steering wheel play is over 3...

Page 117: ...7 TO STOP THE ENGINE TO STOP THE ENGINE If the engine is abruptly stopped before it has If the engine is abruptly stopped before it has cooled down engine life may be greatly cooled down engine life may be greatly shortened Consequently do not abruptly shortened Consequently do not abruptly stop the engine apart from an emergency stop the engine apart from an emergency In particularly if the engin...

Page 118: ...rk F before starting work Run the engine at low idling for 5 minutes Speed up the idling and run the engine at mid range speed Lift the forks slightly and tilt the mast forward to the stroke end to relieve hydraulic pressure Do not leave hydraulic pressure relieved for Do not leave hydraulic pressure relieved for more than 30 seconds more than 30 seconds Tilt back to the stroke end to relieve hydr...

Page 119: ...ground and floor conditions grade speed loading dynamic and static forces and the judgement exercised by the operator speed loading dynamic and static forces and the judgement exercised by the operator Trucks equipped with attachments behave as partially loaded trucks even when operated Trucks equipped with attachments behave as partially loaded trucks even when operated without a load on the atta...

Page 120: ...l Hard braking and wheel sliding are dangerous increase wear and can and wheel sliding are dangerous increase wear and can cause you to loose a load and damage to the lift truck cause you to loose a load and damage to the lift truck Can cause tip over Can cause tip over Use the inching pedal and the accelerator pedal in combination to vary lift and travel speeds independently The further you depre...

Page 121: ...g direction and speed Changing direction and speed The gear selector is designed for the mounting on the left side of the steering column The positions speeds 1 to 3 are selected by a rotary motion the driving direction Forward F Neutral N Reverse R by tilting the gear selector lever A neutral lock is installed as protection against inadvertent drive off Position N Gear selector lever blocked in t...

Page 122: ...g wheel into the desired direction You can turn the truck to the left or right by 52 degree Do not turn the truck abruptly when traveling Do not turn the truck abruptly when traveling at high speed and avoid turn on a slope at high speed and avoid turn on a slope Steering does not function with engine OFF Steering does not function with engine OFF Precautions when driving Precautions when driving ...

Page 123: ...ing for 5 minutes Stopping the truck Stopping the truck Press the brake pedal to stop the truck Put the gear selector lever in the neutral position Turn the parking brake switch ON 6 6 Gear selector lever Parking brake switch 50D9OP14 50D9OP07 ...

Page 124: ...ne stopped Check the leakage of oil and water the work equipment and the exterior of the truck Refill the fuel tank Remove any debris inside of the engine room and attached to the truck 7 7 8 8 5 minute warming up Gear selector lever Parking brake switch 50D9OP20 TRAVELING ON A SLOPE TRAVELING ON A SLOPE Never travel down a slope in neutral Lower the forks 15 20 cm 6 8 in to the ground Never turn ...

Page 125: ...tection 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 be...

Page 126: ... gear state It makes the brake oil overheated due to excessive brake operation It makes the brake oil overheated due to excessive brake operation PRACTICE SAFE OPERATION EVERY TIME YOU USE YOUR TRUCK PRACTICE SAFE OPERATION EVERY TIME YOU USE YOUR TRUCK Careful driving and operation is your responsibility Be completely familiar with all the safe driving and load handling techniques in this Operato...

Page 127: ...aised except to pick up or deposit a load over a rack or stack Slack chains mean rail or carriage hang up Raise the mast before you move If the mast Slack chains mean rail or carriage hang up Raise the mast before you move If the mast malfunctions in any way or becomes stuck in a raised position operate the lift control to malfunctions in any way or becomes stuck in a raised position operate the l...

Page 128: ...lide easier Unlock the fork locking pins Position the forks by pushing them away from you Secure the fork locking pins 2 2 160D7OM134 LOAD ON FORKS LOAD ON FORKS Do not elevate the load with one fork 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 1 3 3 50D9OM137 Do not elevate the load with the ends of th...

Page 129: ...ever 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...

Page 130: ...r 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 ...

Page 131: ...rther lift the load high enough to clear the top of the stack Slowly move the load into position Use care not to damage or move adjacent loads When the load is aligned with the stack beneath it tilt the mast to the vertical position and carefully lower the load onto the top of the stack Lower the forks slightly to clear the load pallet Tilt the forks forward slightly if necessary D35AOM137 D35AOM1...

Page 132: ...oad 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...

Page 133: ...ake 50D9OM31 Low idling for 5 minutes 50D9OP07 IN ADDITION WHEN LEAVING THE TRUCK IN ADDITION WHEN LEAVING THE TRUCK UNATTENDED UNATTENDED Tilt the mast forward until the forks are level and flat on the ground Let the engine run at idle speed Turn the starting switch to the OFF position and remove the key Block the wheels if the truck must be left on an incline or you have any doubt about the truc...

Page 134: ...a 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 This is to avoid the danger of gas poisoning 2 1 AFTER STORAGE After storage When it is kept...

Page 135: ... and the loading dock Ensure that the transporter cannot move by applying the brake and putting blocks under the wheels Put the directional control lever in the NEUTRAL position 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 After checking that the t...

Page 136: ... the truck Use long wire rope and stay to keep the distance with the machine as it should avoid touching with the truck body Put a rubber plate or special stay where contact with the truck s body to prevent damage Place crane on the proper place Install the wire rope and stay like the illustration Make sure wire rope is proper size Make sure that the truck is shut down before hoisting Lifting the ...

Page 137: ...e or block the drive wheels on the disabled truck while working around it When possible raise the carriage forks on the disabled truck about 300 mm 12 in from the floor or ground Secure the carriage with a chain Obtain another lift truck of equal or larger size carrying a partial load for traction Check that the counterweight bolts are in place and properly torqued This bolt is made of a special h...

Page 138: ...use injury or death to personnel near it injury or death to personnel near it Park the disabled truck in authorized areas only Fully lower the forks to the floor put the 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 rolli...

Page 139: ...6ES02 3 Check the clearance A between the differential carrier 2 and the piston housing 3 and the clearance B between the cover 4 and the piston housing 3 Clearance Clearance A B minimum 3 mm The parking brake will be released when The parking brake will be released when the clearance is formed anyone of A or the clearance is formed anyone of A or B B 2 2 4 A B 5 1 In case of malfunction of transm...

Page 140: ...tor 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 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 battery charging areas or near batteries An explosion can result and cause injury or death Hy...

Page 141: ...eys fans or other parts that move Do not touch hot manifolds that can cause sever burns Start the engine on the jumper vehicle and run the engine at a moderate speed for a minimum of five minutes 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 jum...

Page 142: ...n 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 depend on the particular application and lift ...

Page 143: ...er s specifications Always wear safety glasses Wear a safety hard hat in industrial plants and in special work areas where protection is necessary and required Properly ventilate work area vent exhaust fumes and keep shop clean and floors dry Avoid fire hazards and have fire protection equipment present in the work area Do not use an open flame to check for level or leakage fuel electrolyte or coo...

Page 144: ...other parts must be checked to assure that drift or leakage has not developed to the extent that it would create a hazard When working on the hydraulic system be sure the engine is turned off mast is in the fully lowered position and hydraulic pressure is 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 p...

Page 145: ...edures Always use genuine HYUNDAI or HYUNDAI approved parts When removing tires follow industry safety practices Most importantly deflate pneumatic tires completely prior to removal Following assembly of tires on multi piece rims use a safety cage or restraining device while inflating Use special care when removing heavy components such as counterweight mast etc Be sure that lifting and handling e...

Page 146: ... 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 ...

Page 147: ...of truck Use genuine parts Use the recommended oil Remove the dust or water around the inlet of oil tank before supplying oil Drain oil when the temperature of oil is warm Do not repair anything while operating the engine Stop the engine when you fill the oil Relieve hydraulic system of the pressure by opening of breather when repairing the hydraulic system Confirm if the cluster is in the normal ...

Page 148: ...ding to the EPA regulation 1 Air induction system 2 Fuel system 3 Ignition system 4 Exhaust gas recirculation systems 5 After treatment devices 6 Crankcase ventilation valves 7 Sensors 8 Electronic control units 5 6 1 2 ö Replace the O ring and gasket at the same time when replacing the hose Replace clamp at the same time if the hose clamp is cracked when checking and replacing hose ö ö Periodical...

Page 149: ...axle 9 Transmission 10 Torque converter 11 Engine 12 Steering cylinder 13 Hydraulic pump 14 Steering axle 15 Rear wheel 16 Precleaner 17 Air cleaner 18 Radiator 19 Seat 20 Cabin 21 Steering wheel 22 Silencer 23 Propeller shaft 24 Counterweight 17 1 2 3 6 5 4 7 8 20 19 23 9 10 11 15 12 14 22 24 18 13 21 16 50D9OM21 MAJOR COMPONENTS LOCATION 1 ...

Page 150: ...EF level ÂHydraulic oil level ÂFan and fan belt damage and tension Function tests ÂHorn and lamp ÂGauges and instrument panel ÂWarning light ÂService brake and inching operation ÂParking brake operation ÂAccelerator and engine speed operation ÂDirectional and speed control operation ÂSteering wheel operation ÂNoise and vibration Service Remarks Every 50 hours service 2 Check items 7 40 7 43 7 43 7...

Page 151: ...Brake line filter strainer Charge air cooler Air conditioner filter Lubrication Lift chain Mast roller and pin Lift cylinder rod end Lift cylinder tube end Tilt cylinder rod end Tilt cylinder tube end Steering cylinder rod end Steering cylinder tube end Attachment option cylinder rod end Attachment option cylinder tube end Steering axle wheel bearing Pedal pivot Check Clean Replace Check Refill Ch...

Page 152: ...l strainer Service Remarks 7 35 7 23 7 34 Every 2000 hours service Every 2000 hours service 8 8 Check items Clean Replace Replace Hyd suction strainer Radiator coolant Hydraulic oil 2 Service Remarks 2 Conventional hydraulic oil 7 34 7 31 Every 5000 hours service Every 5000 hours service Every 4000 hours service Every 4000 hours service 10 10 Check items Check items Replace Replace Hydraulic oil 3...

Page 153: ...ubrication system ÂEngine oil ÂEngine oil filter cartrige Engine cooling system ÂCoolant ÂRadiator ÂFan belt Engine air intake system ÂAir cleaner element Engine exhaust sysem ÂAftertreatment DEF dozing unit filter Hydraulic tank ÂHydraulic oil ÂHydraulic oil suction strainer ÂReturn oil filter element ÂAir breather element Hand pump cabin tilt ÂHydraulic oil Tire air pressure Service Remarks 7 29...

Page 154: ...pen the cap or drain plug to avoid injury by unexpected spouting of high temperature fluid or gas Open the cap slowly to relieve pressure Always keep the surface of control instrument panels clean in case of damage or malfunction detected in panel replace it with a new one For other details refer to the service manual MAINTENANCE LOCATIONS 1 ö ö ö ö ö ö 5 MAINTENANCE CHART CAUTION ...

Page 155: ...heck Add EO 18 1 27 Steering axle linkage and support Check Lubricate G 6 Initial 100 Hours 1 Differential gear oil Change GO 12 5 1 1 Differential gear oil strainer Clean 1 6 Transmission oil Change EO 18 1 18 Transmission oil filter Replace 1 250 Hours or monthly 1 Differential gear oil Check Refill GO 12 5 1 12 Charge air cooler Check Clean 1 15 Lift chain tension Check Replace 2 23 Hydraulic o...

Page 156: ... and any safety devices are in place undamaged and attached securely Check the cabin for damage Be sure that it is properly positioned and all mounting fasteners are in place and tight LOAD HANDLING COMPONENTS Inspect the mast assembly load backrest rails carriage rollers lift chains and lift and tilt cylinders Look for obvious wear and maintenance problems and damaged or missing parts Check for a...

Page 157: ... 61 cm 24 in carpenter s square on the top of the block and against the shank Check the fork 51cm 20 in above the blade to make sure it is not bent more than 12 5 mm 0 5 in maximum 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 ...

Page 158: ...nuts Torque loose or replaced items to 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 t...

Page 159: ... performed It is recommended that the service requiring tilting cabin must be carefully performed with a skilled service man Tilting and returning cabin Tilting cabin After keeping clearance of the people except the operator along with sounding horn turn the hand pump lever clockwise and then continuously press the cabin tilt switch to tilt the cabin to right side Returning cabin After keeping cle...

Page 160: ...oir tank HAND PUMP Cap 20mm Full 80D9MI67 Fill and check hydraulic oil for hand pump Open upper cap and fill 0 8 by using funnel After filling operate tilt cylinder 2 3 times and close the cabin completely to check the oil level in tank If necessary fill more oil to keep the level ÂTank capacity 0 7 ÂSystem total capacity 1 2 5 Do not operate cabin tilting function while the power is ON or engine ...

Page 161: ...nutes Do not operate unless the oil level is in the normal range L Dipstick Dipstick H REPLACEMENT OF ENGINE OIL AND OIL FILTER Warm up the engine until the water temperature reaches 60 C 140 F Remove the oil drain plug Drain the oil immedi ately to be sure all the oil and suspended con taminants are removed from the engine A drain pan with a capacity of 30 liters 7 9 U S gallons will be adequate ...

Page 162: ... 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 Oil Operate the engine at low idle and inspect for leaks at the filter and the drain plug Shut the engine off and check the oil level with the dipstick Allow 15 minutes for oil to drain down before checking Tighten the engine oil drain plug Plastic oil p...

Page 163: ... it is damaged Do not remove the surge tank cap from a hot engine Wait until the coolant temperature is below 50 C 120 F before removing the radiator cap Heated coolant spray or steam can cause personal injury Do not add cold coolant to a hot engine engine castings can be damaged Allow the engine to cool to below 50 C 120 F before adding coolant 3 1 2 3 4 ö 80D9MI30 FULL LOW A 2 B 1 50D9ENG03 1 Su...

Page 164: ...ties for guidance as to proper handling of used antifreeze 4 1 侍 Wait until the temperature is below 50 C 122 F before removing the coolant system pressure cap Failure to do so can cause personal injury from heated coolant spray Drain the cooling system by opening the drain valve on the radiator and opening the drain valve on the bottom of the engine oil cooler housing A drain pan with a capacity ...

Page 165: ...bove 80 C 176 F Shut the engine off and drain the cooling system 刯 侍 2609A6MA16 OFF 80D9MI10 Fill the cooling system with clean water Be sure to vent the engine and aftercooler for complete filling Do not install the surge tank cap or the new coolant filter Operate the engine for 5 minutes with the coolant temperature above 80 C 176 F Shut the engine off and drain the cooling system If the water b...

Page 166: ...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 2609A6MA43 3 刮 侍 侍 刯 侍 Install the pressure cap Operate the engine until it reaches a temperature 80 C 176 F and check for coolant leaks Check the coolant...

Page 167: ...direction of the fan air flow Visually inspect the radiator for bent or broken fins 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 Visually inspect the radiator for core leaks 550kPa 80 psi NOT OK 80D96MI01 50D96MI02 5 1 2 3 ö 4 CHECK CHARGE AIR COOLER Inspect the charge air cooler for dirt and d...

Page 168: ...ocation of the drive belt on the belt tensioner pulley The belt should be centered on or close to the middle of the pulley Misaligned belts either too far forward or backward can cause belt wear belt roll offs or increase uneven tensioner bushing wear With the belt removed verify that the tensioner arm stop is in contact with the spring case stop If these two are not touching the tensioner must be...

Page 169: ... needed If there is any dam age to the filter body gaskets or endplates do not clean or reuse the filter should be discard ed Always clean filters in a clean environ ment observe strict inspection procedures and repackage filters immediately after the cleaning process with appropriate materials Use observe proper safety precautions and dispose of waste materials in an environmen tally compliant ma...

Page 170: ...water Close drain valve Don t tighten up a drain valve so strong Please inspect and drain water frequently for remain water volume to be less than 1 3 volume of a collection bowl Bowl Drain valve Open Close 10 1 侍 2907A6MI20 Η Θ ö ö Replace element Drain the unit of fuel Follow Drain water instructions above Remove element fuel warmer and bowl from filter head The bowl is reusable do not damage or...

Page 171: ...e plug at the outlet of prefilter Do hand priming the lift pump repeatedly until air bubbles comes out from fuel supply line completely Tighten fuel supply line to its origin position The fuel pump high pressure fuel lines and fuel rail contain very high pressure fuel Do not loosen any fittings while the engine is running Personal injury and property damage can result Wait at least 10 minutes afte...

Page 172: ...indicates proper engagement with the filter If the filter element and equalizing element are removed from the aftertreatment DEF dosing unit they must be discarded and replaced regardless of condition 13 1 ö Η 刯 到 Κ ö 1 2 3 250D9DEF01 290F6MA60 1 DEF dosing unit filter cap 2 DEF filter equalizing element 3 DEF dosing unit filter element Clean and inspect for reuse Inspect the aftertreatment DEF do...

Page 173: ...treament DEF dosing system will not prime until the correct SCR temperatures are reached To verify that there are no DEF leaks test drive the truck for a minimum of 15 mimutes to get the SCR system up to temperature Η 刯 到 ö ö 1 2 3 250D9DEF04 1 DEF dosing unit filter cap 2 DEF filter equalizing element 3 DEF dosing unit filter cartridge 3 DEF AdBlue TANK The DEF AdBlue tank level must be checked d...

Page 174: ...rtreatment system Do not mix additives to DEF AdBlue 2 Η Θ 80D96MA59 LEAKAGE OF FUEL Be careful and clean the fuel hose injection pump fuel filter and other connections as the leakage from these part can cause fire FIRE 15 80D96MA07 OIL LEVEL GAUGE HYDRAULIC OIL CHECK Lower the forks on the ground at a flat location as in the illustration Stop the engine and then leave for about 5 minutes Check th...

Page 175: ...ULIC OIL Lower the forks on the ground and extend the tilt cylinder to the maximum Loosen the cap and relieve the pressure in the tank Prepare a suitable drain pan To drain the oil loosen the drain plug After draining oil tighten the drain plug Fill proper amount of recommended oil Start engine and run continually Release the air by full stroke of control lever The oil must be free of bubbles If b...

Page 176: ...L E M E N T I N HYDRAULIC TANK BREATHER Loosen the cap and relieve the pressure in the tank Loosen the screw and remove the cover Pull out the element Replace the element with a new one Reassemble by reverse order of disassembly ÂTightening torque 1 14 1 74kgfÂm 8 2 12 6lbfÂft Bolt Element Cap Air breather 20 1 2 3 4 5 50D9MI18 Valve Case Element O ring Line filter IN OUT Line filter assy RH side ...

Page 177: ...iner with cleaning oil Install and tighten with specified torque ÂTightening torque 4 5 5 5 kgfÂm 32 5 39 8 lbfÂft 22 1 2 3 LUBRICATE RCV LEVER Remove bellows and grease the joint A and the sliding parts B Bellows A B 23 160D7MI25 P A1 PS A2 PP B T3 T1 PS1 B2 2 3 1 Cut off valve 50D9MI24 ...

Page 178: ... or overinflated The three major causes for excessive heat and pressure of tire are insufficient 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...

Page 179: ...rmation Η Θ Ι Κ ö Tread Valve Side wall Carcass Bead REPLACEMENT OF TIRE Disassembly reassembly replacement and repair of tire requires special skills and equipment Contact a tire repair shop Tires to be replaced Tires with broken or bent bead wires Tires exposed more than 1 4 of carcass fly Tires whose carcass is damaged more than 1 3 of the tire width Tires which show fly separation Tires which ...

Page 180: ...pecified tighten torque ÂTightening torque 61 2 kgfÂm 443 lbfÂft 1 8 6 4 2 7 5 3 4 Η Θ Ι 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...

Page 181: ...il contact is obtained and pull it out again On the oil level gauge the oil level must be lying in the zone HOT Insert the oil level gauge again and tighten it by clockwise rotation When checking apply the parking brake and fix the tires with blocks Level gauge HOT COLD ZONE HOT REPLACEMENT OF TRANSMISSION OIL AND FILTER ELEMENT Operate the truck for a few minutes in order to warm the transmission...

Page 182: ...e 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 Mount the drain plug of the transmission after cleaning it Fill the oil through the level gauge inlet and check if the oil is at the appropriate level The proper oil amount is 18 liters 4 8 U S gallons As the truck is hot after operation wait until the temperature has dropped ...

Page 183: ...ar in parallel to the ground the ground 50D9MI48 DIFFERENTIAL CASE DIFFERENTIAL CASE Differential oil Differential oil Park the truck in a level place Set the mast vertical and raise the forks approx 1m Put blocks under the fork carriage Then stop the engine and apply the parking brake Oil level check Oil level check Remove the level gauge and check the oil level In case of planetary gears remove ...

Page 184: ... 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 1 2 31 Η Θ Ι Κ Λ Μ Ν Cover Bolt Fork retainer Hanger bar 50D7AMS07 FORKS REPLACEMENT Lower the fork carriage until the forks are approximately 25 mm 1 in from the floor Release the fork retainer and remove the cover...

Page 185: ...ng Dust seal are mounted on the rotating part of working device to extend the lubricating interval Mount the lip to be faced out side when replace the dust seal If it is assembled in wrong direction it will cause fast wear of pin and bushing and create noise and vibration during operation Make sure the seals are not damaged or deformed 33 1 2 3 ö 4 ö ö ö WORK EQUIPMENT SUPPORT When carrying out in...

Page 186: ...ng out any electric welding on the machine the battery cables should be disconnected and the connectors pulled out of the electronic control units MCU ECU TCU cluster etc Connect the earth ground lead of the welding equipment as close to the welding points as possible Do net weld or flame cut on pipes or tubes that contain flammable fluids Clean them thoroughly with nonflammable solvent before wel...

Page 187: ... 3 50D9MI58 50D96MI50 When using the air conditioner for a long time open the window once every one hour Be careful not to overcool the cab The cab is properly cooled if the operator feels cool when entering there from outside About 5 C lower than the outside temperature When cooling change air occasionally CHECK DURING SEASON Ask the service center for replenishment of the refrigerant or other ma...

Page 188: ...al warming Do not release refrigerant into the environment Safety precautions Work on the air conditioning system must only be performed by a qualified service technician Do not attempt to preform work on the air conditioning system Wear safety goggles chemical resistant gloves and appropriate personal protective equipment to protect bare skin when there is a risk of contact with refrigerant Actio...

Page 189: ...as it is acid Be careful not to get the electrolyte in the eyes Be careful not to get the electrolyte in the eyes Wash with clean water and go to the doctor if it Wash with clean water and go to the doctor if it enters the eyes enters the eyes 1 1 2 2 36070FW05 Recycle Recycle Never discard a battery Always return used batteries to one of the following locations A battery supplier An authorized ba...

Page 190: ...k Filter Drain plug 50D7AOM19A Prior to reinstall the cable inspect in detail and Prior to reinstall the cable inspect in detail and 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 abnormal damages such as cracking and wear abnormal damages such as cracking and wear out of ...

Page 191: ...mpressed air 4 1 Radiator cleaning Close the drain valves and add clean soft water City water etc through the water filler Add the radiator cleaner and run the engine at idling speed for 15 minutes Stop the engine and drain water from the drain valves Add clean water and run at idling speed 5 to 10 minutes Then stop the engine and drain water Close the drain valves and fill the radiator with clean...

Page 192: ...sition When jacking up the truck never go under the truck For wheels using a separate type rim check first that the rim nut is not loose before loosening the lug nuts Be careful not to mistake the rim nuts and lug nuts When assembling separated type rims with bolts and nuts check any damage and tighten them to the specified tightening torque Change the bolts and nuts with new ones after using twic...

Page 193: ... 15A 20A 60A 10A 10A 10A 15A 10A 10A 10A 10A 10A 10A CR 61 CR 56 CR 39 CR 42 CR 63 CR 62 WIRE DIRECTION COVER P N 2DFQ 10310 STOP LAMP RMCU MONITOR CLUSTER RADIO START RELAY 20A CR 26 CR 4 5A IG IG AIR CON MAIN AIR COMP CONDENSER CR 36 10A HORN CAB TILT CLUSTER MCU TCU B 10A DEF SENSOR MODULE HEATER DEF 10A LINE HEATER DEF 20A AIRCON ROOM LAMP 5A FUEL HEATER ECM IG TCU IG HEAD LAMP WORK LAMP REAR ...

Page 194: ...tart 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 1 2 8 Indicator lights Check that all lights are functioning and indicate normal truck operation as described in section 3 Know your truc...

Page 195: ...r 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 Auxiliary controls Option If your lift truck is equipped with an attachment test the control leve...

Page 196: ...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 Put the directional control in FORWARD Press the inching pedal fully down and hold Depress the accelerato...

Page 197: ...nstalled 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 Engine cooling system To check the engine coolant level open the hood to the ...

Page 198: ...evel 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 t...

Page 199: ...he excess grease from all points after lubricating Lubricate miscellaneous linkage as needed 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 support bushings Lift chains Lubricate the entire length of the mast rail lift and carriage chains with HYUNDAI chain a...

Page 200: ...intenance 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 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...

Page 201: ...m 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 Ad...

Page 202: ...ension If it is too slack adjust the tension SEE SECTION 8 SPECIFICATIONS In case of overheating do not stop the engine immediately Run the engine at low idling Open the hood to ventilate the engine compartment When the water temperature drops stop the engine Check the cooling water level If it is low add more water Wear safety glasses and a face shield when using compressed air Never touch the ra...

Page 203: ...ctrolyte 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 CARE AFTER DAILY OPERATION Drain water from the fuel system to prevent freezing 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...

Page 204: ...g Grease Institute ȵASTM American Sociery of Testing and Material Description Specification Engine oil 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侏1 Grease Lithium base grease NLGI No 2 Fuel ASTM D975 No 2 Coolant Mixture of 50 ethylene glycol base a...

Page 205: ...Torque converter transmission Transmission oil 18 4 8 Axle Gear oil 12 5 3 3 Hydraulic oil tank Hydraulic oil 132 34 9 Cabin tilt hand pump Hydraulic oil 0 7 0 2 Fuel tank Diesel fuel侏1 171 5 45 3 Fitting Grease nipple Grease Brake oil Hydraulic oil Radiator Antifreeze Soft water 20 4 5 4 DEF AdBlue tank Mixture of urea and deionized water 18 9 5 SAE 30 SAE 10W SAE 10W 30 SHELL DONAX TD SAE 15W 40...

Page 206: ... 9 2 4 1200 150 65 47 2 5 9 2 6 1200 180 70 47 2 7 1 2 8 Mast Tilt angle forward backward C C degree 15 10 Max height D mm ft in 4275 14 0 4375 14 4 Min height E mm ft in 2515 8 3 2675 8 9 Body Travel speed Unload km h 33 9 33 7 33 6 35 Gradeability Load 58 7 50 6 44 4 35 2 Min turning radius Outside F mm ft in 3314 10 10 3374 11 1 3436 11 3 3700 12 2 ETC Max hydraulic pressure kgf cm2 210 Hydraul...

Page 207: ...2 1 Rated gross horse power ps rpm 102 2200 Maximum gross torque at rpm kgf余m rpm 42 3 1600 Engine oil quantity 再 U S gal 12 3 2 Dry weight kg lb 348 767 High idling speed rpm 2450 Low idling speed rpm 850 Rated fuel consumption g kw hr 220 at 1600 rpm Starting motor V kW 24 4 8 Alternator V A 24 80 Battery V AH 24 80 Item Unit Specification Type 0 Axial piston variable gear pump Displacement cc r...

Page 208: ...74 RR 1 4 711 2 2 340 3 0 974 Axle Type Front wheel drive type fixed location Gear ratio 10 545 Gear Ring pinion gear type Wheels Q ty FR RR Double 4 2 Front drive 8 25 15 14 PR Rear steer 8 25 15 14 PR Brakes Travel Front wheel wet disc brake Parking Wet disc negative brake Steering Type Full hydraulic power steering Steering angle 75 87 to both right and left angle respectively Item Unit Specifi...

Page 209: ...um gross torque at rpm kgf余m rpm 42 3 1600 Engine oil quantity 再 U S gal 12 3 2 Dry weight kg lb 348 767 High idling speed rpm 2450 Low idling speed rpm 850 Rated fuel consumption g kw hr 220 at 1600 rpm Starting motor V kW 24 4 8 Alternator V A 24 80 Battery V AH 24 80 Item Unit Specification Type 0 Axial piston variable gear pump Displacement cc rev 35 6 33 7 6 Maximum operating pressure kgf cm2...

Page 210: ...e type fixed location Gear ratio 12 4 Gear Ring pinion gear type Wheels Q ty FR RR Double 4 2 Front drive 9 00 20 14 PR Rear steer 9 00 20 14 PR Brakes Travel Front wheel wet disc brake Parking Wet disc negative brake Steering Type Full hydraulic power steering Steering angle 75 04 to both right and left angle respectively Item Unit Specification Type 0 Load sensing Non load reaction Dynamic signa...

Page 211: ...olt M10 1 5 6 9 1 4 50 10 1 7 Power train system Transmission mounting bolt nut M16 2 0 7 5 54 8 Torque converter mounting bolt M10 1 5 6 9 1 4 50 10 1 9 Drive axle mounting bolt nut M27 3 0 150 15 1085 109 10 Steering axle mounting bolt nut M18 2 5 41 3 6 2 299 44 8 11 Front Rear wheel mounting nut M22 1 5 61 2 12 443 86 8 12 Propeller shaft To axle TM 3 8 24UNF 7 0 7 50 6 5 0 13 Others Counterwe...

Page 212: ...uantity Replace with specified fuel Lack of fuel Air mixed in fuel system Fuel injection pump or nozzle defec tive Starting motor rotates slowly Engine compression insufficient Valve clearance out of adjustment Add fuel Repair Replace See Electrical system Adjust clearance Thermostat faulty Water temperature gauge faulty Replace Replace Radiator fin clogged or fin damaged Thermostat or water temp ...

Page 213: ... warning lamp does not light when enig ne is stopped with starting switch left in ON position Caution lamp defective Caution lamp switch defective Replace Replace Faulty wiring Glow plug damaged Check and repair Replace Faulty wiring Insufficient battery voltage Check and repair Recharge battery Insufficient battery voltage Starting motor defective Recharge battery Replace Insufficient battery vol...

Page 214: ...free wheel malfunctioning Air sucked in Water intruding into transmission case Bearing worn or seizing Gauge malfunctioning Clutch dragging Bearing worn or seized Check oil level Add or drain oil as necessary After draining oil from oil tank and transmission check and replace interfering parts Check enigne stalling speed If necessary replace Check the inlet side joint or pipe If necessary retighte...

Page 215: ...l Check joints and pipes If necessary retighten joint or repla ce packing Check and replace Check oil pressure If necessary rep lace pump Check spring tension If necessary replace Disassemble check and repair or re place Disassemble check measure and re place Check stalling speed Increased engine load will cause ex cessive drop of stalling speed Check oil temperature rise If any replace free wheel...

Page 216: ...r defects and replace Probable cause Remedy 5 Power is not transmitted 1 Torque converter 2 Transmission Clutch plate damaged Low oil level Oil pump driving system faulty Shaft broken Lack of oil pressure Low oil level Inching valve and link lever improper ly positioned Forward reverse spool and link lever improperly positioned Clutch fails to disengage 1 Clutch case piston ring defective 2 Main s...

Page 217: ...rack Disassemble and check for wear of seal lips and mating sliding surfaces pump boss coupling etc Replace oil seal pump boss coupl ing etc Check and retighten or replace pack ing Check and repair or replace gasket Check and retighten or gasket Check and replace cracked part Foreign matter intruding into oil pass age to clutch Shaft spline worn Disassemble check and repair or replace Disassemble ...

Page 218: ...t air bleeding Oil pump Oil inlet pipe sucks air Valve Faulty Unbalance oil pressure Piping Pipe from pump to power steering dented or clogged Insufficient air bleeding Flow control valve orifice clogged Piping Pipe from tank to pipe dented or clogged Retighten Replace Adjust Bleed air Adjust valve set pressure and check for specified oil pressure Repair or replace Add oil Repair Bleed air complet...

Page 219: ...qually inflated Brake out of adjustment Disk surface roughened Wheel bearing out of adjustment Hydraulic system clogged Adjust tire pressure Adjust Repair by polishing or replace Adjust or replace Clean Repair and add oil Bleed air Replace Repair or replace Clean Probable cause Remedy 3 Brake trailing Pedal has no play Piston cup faulty Brake valve return port clogged Hydraulic system clogged Whee...

Page 220: ... Oil leaks from joint or hose Excessive restriction of oil flow on pump suction side Relief valve fails to keep specified pressure Poor sealing inside cylinder High hydraulic oil viscosity Mast fails to move smoothly Oil leaks from lift control valve spool Oil leaks from tilt control valve spool Excessive restriction of oil flow pump suction side Gear or bearing in hydraulic pump defective Foreign...

Page 221: ...smoothly Deformed masts or carriage Faulty hydraulic equipment Damaged load and side rollers Unequal chain tension between LH RH sides LH RH mast inclination angles are unequal Mast assembly is twisted when tilted Disassembly repair or replace See Troubleshooting Hydraulic Cylinders pump and control valve in section 6 hydraulic system Replace Adjust chains Adjust tilt cylinder rods Abnormal noise ...

Page 222: ...easons such as overloading glancing blows against walls and objects and picking up load unevenly Difference in fork tip height If the measured value exceeds the allowance replace fork Fatigue Fatigue failure may result from the fatigue crack even though the stress to fork is below the static strength of the fork Therefore a daily inspection should be done Crack on the fork heel Crack on the fork w...

Page 223: ...D ADJUSTING EASE OF STARTING NOISE EASE OF STARTING NOISE Set gear shift lever at NEUTRAL IDLING IDLING After warming up engine run at idling Check that engine maintains steady smooth rotation without gasping abnormal noise abnormal explosions or irregular vibration Check that idling speed is within specified range Idle rpm SEE 8 SPECIFICATION 1 1 2 3 4 1 2 3 4 5 1 1 2 2 Turn the parking brake swi...

Page 224: ...he 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 1 2 3 5 5 ENGINE OIL ENGINE OIL Check oil level with dipstick and add oil if necessary Check oil for dis...

Page 225: ...center distance the belt tension must be adjusted Inspect the fan belt for damage Transverse across the belt cracks are acceptable Longitudinal direction of belt ribs cracks that intersect with transverse cracks are not acceptable Inspect the belt Embedded debris Uneven excessive rib wear Exposed belt cords Glazing high heat If any of the above conditions are present If any of the above conditions...

Page 226: ...rse solenoid valve operates and oil comes to reverse clutch thus the truck will run backward OIL LEAKAGE OIL LEAKAGE Check that there is no oil leakage from torque converter transmission or control valve If oil oozes out and forms drops replace packing 1 1 2 2 1 1 2 2 ADJUSTMENT OF PEDAL ADJUSTMENT OF PEDAL Accelerator pedal Accelerator pedal Pedal operation range is A If the range is differ much ...

Page 227: ...l 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 3 3 1 2 22m m H 50D7ATA05 ...

Page 228: ...ICATIONS 2 2 RIM SIDE RING RIM SIDE RING Check rim side ring for deformation or cracks Check visually or use crack detection method Rear rim connecting nut torque SEE SECTION 8 SPECIFICATIONS 3 3 D35ATA15 STEERING AXLE STEERING AXLE Push axle in from one side or measure front to rear clearance with feeler gauge Check that clearance is within 2 mm If clearance is more than 2mm insert shim to reduce...

Page 229: ...nge should be 30 60 mm at rim of steering wheel If play is too large adjust at gearbox Test steering wheel play with engine at idling 30 60mm 1 2 2 4 in 1 1 2 2 STEERING AXLE STEERING AXLE Put camber gauge in contact with hub and measure camber If camber is not within 1 0 5 rear axle is bent Ask assistant to drive truck at minimum turning radius Fit bar and a piece of chalk at outside edge of coun...

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