Hyundai 50DS-7E User Manual
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Hyundai 50DS-7E User Manual

Hyundai 50DS-7E User 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) -------------------------------------------------------------------- 0-12
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 -------------------------------------------------------------------------------------------------------------------- 2-5
8. Pallets and skids ----------------------------------------------------------------------------------------------------------- 2-5
CONTENTS
CONTENTS

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Summary of Contents for Hyundai 50DS-7E

  • 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) -------------------------------------------------------------------- 0-12 1. SAFETY HINTS 1.
  • Page 2 9. Caution for electrical lines -------------------------------------------------------------------------------------------- 2-6 10. Lifting loads ------------------------------------------------------------------------------------------------------------------- 2-7 11. Side shift ------------------------------------------------------------------------------------------------------------------------ 2-8 12. Fork positioner -------------------------------------------------------------------------------------------------------------- 2-9 3. KNOW YOUR TRUCK 3. KNOW YOUR TRUCK 1. General locations ---------------------------------------------------------------------------------------------------------- 3-1 2. Data/safety plates and decals ------------------------------------------------------------------------------------- 3-2 3.
  • Page 3 4. Planned maintenance intervals ----------------------------------------------------------------------------------- 7-8 5. Maintenance chart -------------------------------------------------------------------------------------------------------- 7-12 6. How to perform planned maintenance ----------------------------------------------------------------------- 7-14 7. Replacement and check ---------------------------------------------------------------------------------------------- 7-17 8. Lubrication chart ------------------------------------------------------------------------------------------------------------ 7-33 9. Greasing point --------------------------------------------------------------------------------------------------------------- 7-34 10. Handling machine in extremely hot places ----------------------------------------------------------------- 7-35 11.
  • Page 4 2002/88/EC, 2004/26/EC, 2006/105/EC) and noise emission 2000/14/EC (amended by 2005/88/EC). Forklifts Model : ******* Serial Nr. : 2. Manufacturer Hyundai Heavy Industries Co. Ltd. 1000, Bangeojinsunhwan-doro, Dong-Ku Ulsan The republic of Korea Hyundai Heavy Industries Europe N.V. Authorized representative : Vossendal 11 Owner of the technical fi...

  • Page 5: 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 6: 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 7: 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 8 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 9: Ec Regulation Approved

    EC REGULATION APPROVED EC REGULATION APPROVED · Noise level (2000/14/EC and EN 12053) are as followings. Model (EU only) 50DS/60DS/70DS-7E 107 dB 82 dB ·The value of vibrations transmitted by the operator's seat are lower than standard value of (2005/88/EC)

  • Page 10: 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 new labels. VIEW -A- START SWITCH DASHBOARD COVER FAN SHROUD DASHBOARD 50DS7EOM101 Logo 13 Temperature 23 Label (UL) Warning plate 14 Parking brake...
  • Page 11 2. DESCRIPTION 2. DESCRIPTION There are several specific warning labels on this machine please become familiarized with all warning labels. Replace any safety label that is damaged, or missing. 1) 1) WARNING PLATE WARNING PLATE (item 2) This warning label is positioned on the both side of the mast.
  • Page 12 4) 4) 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 forbid to open the filler cap of the radiator because operator might get scalded due to spouting of hot water.
  • Page 13 7) 7) HOOK HOOK (item 16) This warning label is positioned respectively on the both top side of mast and near rear tire of the both side of the main frame. Refer to page 7-39 for safe loading Refer to page 7-39 for safe loading procedures.
  • Page 14 START WARNING START WARNING (item 10) This warning and caution plate are located on the right side of the dashboard cover. 5 6’ Start key switch after 5~6 seconds from Start key switch after 5~6 seconds from 92AD-00920 ※ ON position. It needs approx 5~6 ON position.
  • Page 15 WARNING SAFETY WARNING SAFETY (item 15) This warning label is positioned on the front inside of overhead guard stay-RH. 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 machine, always pull the parking brake lever so that the machine can keep with stopping condition.
  • Page 16 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. TPEM TPEM (item 32) This label is located on the front side of the dashboard.

  • Page 17: Guide (Direction, Serial Number, Symbols)

    GUIDE GUIDE 1. DIRECTION 1. DIRECTION The directions of this machine indicate forward, Front backward, right and left when machine is in the travelling direction. Right Left Rear D255SM01 2. SERIAL NUMBER 2. SERIAL NUMBER Inform following when you order parts or the machine is out of order. MACHINE SERIAL NUMBER It's shown on front of the right side frame.

  • Page 18: 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 19: 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. D35AOM04 Don't smoke in NO SMOKING areas or when refueling. D35AOM06...
  • Page 20 Don't operate the truck outdoors in rainy day. ※ Exclude the truck equipped cabin. Exclude the truck equipped cabin. D35AOM07 Exhaust gas is dangerous. Do not operate the truck at the inhouse, if possible. Provide adequate ventilation when working in a closed space. D35AOM08...

  • Page 21: Seat Belts

    3. SEAT BELTS 3. SEAT BELTS A l w a y s b u c k l e u p f o r t h e m a c h i n e A l w a y s b u c k l e u p f o r t h e m a c h i n e equipped with safety belt.

  • Page 22: No Riders

    4. NO RIDERS 4. NO RIDERS The operator is the only one who should be on a truck. D255OM11A Never transport personnel on the forks of a lift truck. D255OM12A...

  • Page 23: 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. D35AOM13 Watch for people in your work area even if your truck has warning lights or alarms.

  • Page 24: Operator Protection

    6. OPERATOR PROTECTION 6. OPERATOR PROTECTION Keep under the overhead guard. Always keep your body within the confines of the truck. Do not operate truck without overhead Do not operate truck without overhead guard, unless condition prevent use of a guard, unless condition prevent use of a guard.

  • Page 25: 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. D255OM12A Always lower the load slowly. Raise and lower with mast vertical or tilted slightly back(Never forward).

  • Page 26: 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. D255OM62 Never try to repair the mast, carriage, Never try to repair the mast, carriage, chain, or attachment by yourself.

  • Page 27: 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 28: 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 D255OM26A Loaded - Forks upgrade D255OM27A 1-11...

  • Page 29: Tip Over

    11. TIP OVER 11. TIP OVER 1) 1) LATERAL TIP OVER LATERAL TIP OVER Lateral tip over can occur with a combination of speed and sharpness of turn. This combination will exceed the stability of the truck. This condition is even more likely with an unloaded truck.
  • Page 30 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 31: 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 32: Parking

    13. PARKING 13. PARKING Never park on a grade. D35AOM33 Always come to a complete stop before leaving truck. Be sure travel control is in NEUTRAL. D35AOM34 Lower forks fully to floor and tilt forward. D255OM35A Set parking brake. Position 1 : Lock Position 2 : Release Turn key to OFF position.

  • Page 33: Refueling

    14. REFUELING 14. REFUELING Before adding oil, check around machine for oil leakage. D255OM02 Keep away from fire when adding oil or during operation. D255OM03 After adding oil, wipe off any oil spilled on machine. D255OM04 1-16...

  • Page 34: Step

    15. STEP 15. STEP When getting on or off the machine, use the step provided. D255OM05 Do not jump up or down from the machine. D255OM06 1-17...

  • Page 35: Operator's Safety Rules

    Always buckle up if a seat belt is provided. provided. D35AOM23 Parking brake must be locked in the PARK HYUNDAI POSITION before exiting from the vehicle. 1. Release(Drive) Parking brake must remain locked in the Parking brake must remain locked in the 2.

  • Page 36: Side Shift

    17. SIDE SHIFT SIDE SHIFT Do not put side loads on forks. Do not put side loads on forks. 60DF71SS01 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 machine and may cause over-turning.

  • Page 37: Operating Hazards

    2. OPERATING HAZARDS 2. OPERATING HAZARDS 1. LOOSE LOADS 1. LOOSE LOADS Loose or unbalanced loads are dangerous. Loose or unbalanced loads are dangerous. Observe these precautions. Observe these precautions. Never carry loose or uneven material. D255OM39 Center wide loads. D35AOM40 Stack and band loose material.

  • Page 38: 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 39: 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 40: 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 41: Chain Slack

    7. CHAIN SLACK 7. CHAIN SLACK Slack chains mean rail or carriage hang- Slack chains mean rail or carriage hang- 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...

  • Page 42: Caution For Electrical Lines

    9. CAUTION FOR ELECTRICAL LINES 9. CAUTION FOR ELECTRICAL LINES When moving the machine with the mast When moving the machine with the mast raised, watch out electrical lines over the raised, watch out electrical lines over the machine. machine. The operating near the electrical lines is The operating near the electrical lines is very dangerous.

  • Page 43: Lifting Loads

    10. LIFTING LOADS 10. LIFTING LOADS Never permit any persons to stand or Never permit any persons to stand or pass under lifted load. pass under lifted load. D255OM08 Never use wire rope to lift a load. Never use wire rope to lift a load. D255OM09...

  • Page 44: Side Shift

    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. 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 o v e r t u r n i n g o f t h e f o r k l i f t d u e t o unbalanced weight.

  • Page 45: 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 fork positioner suddenly and quickly. It can be caused to drop the load. 35D7EOM65...

  • Page 46: Know Your Truck

    3. KNOW YOUR TRUCK 1. GENERAL LOCATIONS 50DS7EOM54 Mast Forks 13 Counterweight Lift chain Overhead guard 14 Rear wheel Lift cylinder Turn signal lamp 15 Front wheel Backrest 10 Head lamp 16 Rear combination lamp Tilt cylinder 11 Operator's seat Lift bracket 12 Bonnet...

  • Page 47: Data/Safety Plates And Decals

    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 48 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 49 OPERATOR SAFETY WARNING DECAL 22DF7OM59K 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.

  • Page 50: Instruments And Controls

    3. INSTRUMENTS AND CONTROLS 21 40 26272829 22,23,24 3 4 5 8 9 10 11 0 0 0 0 HYUNDAI HYUNDAI 0 0 0 0 15 16 DETAIL A DETAIL B 30 31 32 33 OIL TEMP 50DS7EOM64 Start switch...

  • Page 51: Indicator Symbols

    4. INDICATOR SYMBOLS FUEL GAUGE E : Empty F : Full Fill fuel tank regularly. Never allow machine to run out fuel. 15D7EOM10K Do not overfill the fuel tank. Always check the fuel level on level ground. Fill the fuel immediately when the warning lamp is turned HOUR METER This indicates the time of total machine operation.
  • Page 52 TRANSMISSION OIL TEMPERATURE WARNING LAMP This lamp informs the operator that transmission oil is above the specified temperature. Transmission oil temperature warning lamp ON : Abnormal Transmission oil temperature warning lamp OFF : Normal When this lamp lights up during operation, stop the engine 60DF7EOM79 and check the machine.
  • Page 53 AIR CLEANER ELEMENT WARNING LAMP This lamp lights up when the replacement time of element is late and the element is dirty, so air influx is not smooth. If this lamp lights up, clear the element or replace it. 77073CD20 HEAD LAMP SIGNAL LAMP This lamp shows that the head lamp lights up or not.
  • Page 54 WATER SEPARATOR LAMP This lamp lights up when the water separator is full of water or malfunctioning. When this lamp lights up, stop the machine and spill water out of the separator. D357OM902 OPERATOR SAFETY LAMP (OPTION) 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 55 Spanner Electronic control unit recognized an error, is flashing Letters STOP Immediate stop is required (At the moment not activated) If it happens error codes, consult with Hyundai service center to repair the fault. 3-10...
  • Page 56 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 57 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 58 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 59 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 60: Operating Lever And Switch

    5. OPERATING LEVER AND SWITCH START SWITCH There are four positions, OFF, ON and START. Before starting, set gear selector lever at N, and pull parking brake. : None of electrical circuits activates. : All the systems of machine operate. Preheat the system for 10~20 seconds.
  • Page 61 REAR WORK LAMP SWITCH (OPTION) This switch is used to operate work lamps. Press this switch to turn on work lamps. L255OM16 BEACON SWITCH (OPTION) This switch turn ON the rotary light. L255OM18 FULL AUTOMATIC SWITCH Manual mode ( ) Press the top of the switch fully for the manual mode of the autoshift function.
  • Page 62 TURN SIGNAL SWITCH This lever makes the turn signal lamp flash. Right turn Turning LEFT : Push lever forward Turning RIGHT : Pull lever backward When the steering wheel is returned to straight, the turn Left turn signal is not cancelled. Return the lever to central position by hand.
  • Page 63 PARKING BRAKE LEVER Position 1 Parking brake is applied and front wheel is locked. Position 2 Parking brake is released. Before moving the truck be sure the parking brake is D35AOM96 released. LIFT LEVER Lift Lift Lower PULL the lever back to lift the load. Lower PUSH the lever forward to lower the load.
  • Page 64 LEVER FOR SIDE SHIFT WITH FORK POSITIONER (OPTION) Fork positioner (synchronizer type) Outstrech the forks Pucker up Push the lever forward to outstrech simultaneously outward Outstrech of the both forks. Pucker up the forks Pull the lever backward to pucker up simultaneously inward of the both forks.
  • Page 65 STEERING WHEEL LOCK LEVER The angle of the steering shell can be adjusted forward and backward. Lock Release Release : Pull the lever backward. Lock : Release the lever. Steering column cover RH side 25L7OM91 METHOD OF ADJUSTING STEERING WHEEL ANGLE Turn the lock lever down.

  • Page 66: 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 67 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 68: 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 69: Fuel Safety Practices

    3. FUEL SAFETY PRACTICES 3. FUEL SAFETY PRACTICES REFUELING DIESEL TRUCKS REFUELING DIESEL TRUCKS 80D7OM106 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 70: 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 71: Check Before Starting

    2. CHECK BEFORE STARTING 2. CHECK BEFORE STARTING 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 72: 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 overhead guard, backrest and forks for crack or obvious damage.
  • Page 73 3) 3) CHECK BRAKE FLUID CHECK BRAKE FLUID Remove reservoir cap, and check level. If necessary, add brake fluid. 35- 5 mm (1.4-3. in) Type Brake fluid Wet type Azolla ZS32 or hyd oil ISO VG32 35DFOM110 4) 4) 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 MAX line.
  • Page 74 6) 6) CHECK FAN BELT TENSION CHECK FAN BELT TENSION The fan belt must depress the specified value when the midpoint between the generator and fan pulley is depressed. If the belt is stretched beyond the adjustment allowance, or If the belt is stretched beyond the adjustment allowance, or there are cuts or cracks, replace the V-belt.
  • Page 75 CHECK HORN AND LAMPS CHECK HORN AND LAMPS Check horn button and lamp switch if operate normally or not. 2 : Horn button 2' : Lamp switch If horn and lamp are malfunctioning, contact your HYUNDAI forklift distributor. 50DF7OM13 CHECK PEDALS CHECK PEDALS Check for any catching or abnormal heaviness when depressing the pedals.

  • Page 76: 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. (1) (1) Forward/Backward adjustment (A) Forward/Backward adjustment (A) ①...

  • Page 77: 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. · The parking brake is applied. ·...

  • Page 78: 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 gear selector lever in NEUTRAL, the seat adjusted, and your seat belt buckled.

  • Page 79: Starting The Engine

    7. STARTING THE ENGINE 7. STARTING THE ENGINE 1) 1) START FROM A SAFE CONDITION START FROM A SAFE CONDITION Before you start the truck, safely seat yourself on the truck, fasten seat belt, apply the parking brake, make sure all controls are in neutral or other correct position, lower the forks fully to floor or ground, put the gear selector lever in NEUTRAL, and make sure you know how to operate the truck and all its controls.

  • Page 80: Check After Starting Engine

    8. CHECK AFTER STARTING ENGINE 8. CHECK AFTER STARTING ENGINE 1) 1) CHECK FOR ABNORMAL NOISE OR VIBRATION CHECK FOR ABNORMAL NOISE OR VIBRATION 2) 2) CHECK ENGINE EXHAUST GAS COLOR CHECK ENGINE EXHAUST GAS COLOR Exhaust gas color Criteria Colorless, light blue Black Check for incomplete combustion...
  • Page 81 4) 4) CHECK MONITOR CHECK MONITOR FUEL LEVEL ENGINE OIL T/M OIL BATTERY AIR CLEANER WATER OPERATOR SEAT BELT ENGINE OVERHEAT WARNING LAMP PRESSURE TEMPERATURE CHARGE ELEMENT WARNING LAMP WARNING LAMP SEPARATOR SAFETY WARNING LAMP WARNING LAMP WARNING LAMP WARNING LAMP WARNING LAMP WARNING LAMP 50DS7EOM126...

  • Page 82: 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 83 3) 3) USING THE ACCELERATOR PEDAL USING THE ACCELERATOR PEDAL With the parking brake released and the gear selector lever in FORWARD or REVERSE, put your foot on the accelerator pedal and push down smoothly until the truck is moving at the desired speed.

  • Page 84: Operating Safely

    10. OPERATING SAFELY 10. OPERATING SAFELY Safe operation is the responsibility of the operator. 1) 1) 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... Before driving, check all around to be sure that your intended path of travel is clear of obstructions and pedestrians.
  • Page 85 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 86: Load Handling

    11. LOAD HANDLING 11. 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 87 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 88 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 89 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 90 7) 7) STACKING STACKING To put a load on a stack To put a load on a stack (1) (1) ① Approach 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 91 (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 92: Shut Down Procedure

    12. SHUT DOWN PROCEDURE 12. 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 93: 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 94 Park the disabled truck in authorized areas only. Fully lower the forks to the floor, put the gear selector lever in the NEUTRAL position and turn the starting switch to the OFF position. Engage the parking brake. Remove the key and, when necessary, block the wheels to prevent the truck from rolling.

  • Page 95: How To Use Battery Jumper Cables

    2. HOW TO USE BATTERY JUMPER CABLES 2. HOW TO USE BATTERY JUMPER CABLES If your lift truck battery is discharged (dead), you can start your lift truck by jumping it from another lift truck that has a 12 V negative-ground electrical system. The "Booster" battery must be fully charged and in good condition.
  • Page 96 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 97: 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 98: 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 99 Before leaving the truck. Stop the truck. Fully lower the load-engaging means: mast, carriage, forks or attachments. Put the gear selector lever 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, overhead guard and frame members must be carefully and regularly inspected and maintained in a safe operating...
  • Page 100 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 101: Instructions Before Maintenance

    3. INSTRUCTIONS BEFORE MAINTENANCE 3. INSTRUCTIONS BEFORE MAINTENANCE 1) 1) INTERVAL OF MAINTENANCE INTERVAL OF MAINTENANCE You may inspect and service the machine 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 0 0 0 0 0 0 area, quarry, sea shore and etc.)
  • Page 102 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 103 5) 5) PERIODICAL REPLACEMENT OF SAFETY PARTS PERIODICAL REPLACEMENT OF SAFETY PARTS These are the parts which the operator cannot judge the remained lifetime of them by visual inspection. Repair or replace if an abnormality of these parts is found even before the recommend replacement interval.

  • Page 104: Planned Maintenance Intervals

    4. PLANNED MAINTENANCE INTERVALS 4. PLANNED MAINTENANCE INTERVALS 1) 1) MAJOR COMPONENT LOCATIONS MAJOR COMPONENT LOCATIONS 8 9 10 11 12 13 14 15 16 17 50DS7EOM21 Mast 10 Priority valve 19 Muffler Lift cylinder 11 Transmission 20 Silencer Tilt cylinder 12 Torque converter 21 Air cleaner Control valve...
  • Page 105 2) 2) MAINTENANCE CHECK LIST MAINTENANCE CHECK LIST (1) (1) EVERY 10 HOURS SERVICE EVERY 10 HOURS SERVICE Check items Service Remarks Visual inspection ·Brake oil. Check, Add ·Truck for obvious damage and leaks. Check, Repair or Replace ·Warning plates and decals. Check, Replace 0-6, 3-4 ·Condition of tires and wheels.
  • Page 106 (3) (3) INITIAL 100 HOURS SERVICE INITIAL 100 HOURS SERVICE Check items Service Remarks Differential gear oil Change 7-20 Transmission oil Change 7-20 Transmission oil filter Replace 7-20 (4) (4) EVERY 250 HOURS SERVICE EVERY 250 HOURS SERVICE Check items Service Remarks Differential gear oil...
  • Page 107 (8) (8) EVERY 5000 HOURS SERVICE EVERY 5000 HOURS SERVICE Check items Service Remarks ·Hydraulic oil * Replace 7-21 Hyundai genuine long life hydraulic oil (9) (9) WHEN REQUIRED WHEN REQUIRED Check items Service Remarks Fuel system 5-12 ·Fuel tank Drain, Clean ·Water separator...

  • Page 108: Maintenance Chart

    5. MAINTENANCE CHART 5. MAINTENANCE CHART D357MA01 ※ 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.
  • Page 109 Radiator coolant Change 21.5 5000 Hours 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 EO : Engine oil...

  • Page 110: How To Perform Planned Maintenance

    6. HOW TO PERFORM PLANNED MAINTENANCE 6. HOW TO PERFORM PLANNED MAINTENANCE 1) 1) VISUAL INSPECTION 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.
  • Page 111 4) 4) FORKS FORKS Inspect the load forks for cracks, breaks, bending, and wear. The fork top surfaces should be level 10% of "A" is max. wear and even with each other. The height difference allowed between both fork tips refer to below table. Fork length Height difference Model...
  • Page 112 6) 6) WHEEL AND TIRES 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 chunking out. Check all wheel lug nuts or bolts to be sure none are loose or missing.

  • Page 113: Replacement And Check

    7. REPLACEMENT AND CHECK 7. 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 (1) (1) Clean Clean ① Wash the terminal with hot water if it is contaminated, and apply grease to the terminals after washing.
  • Page 114 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 115 OSHA approved eye protection rated for 200 kPa (30 psi) is required for air cleaning OSHA approved eye protection rated for 200 kPa (30 psi) is required for air cleaning operation. operation. Replace element if exhaust is black, or if lack of engine power is noted even after cleaning Replace element if exhaust is black, or if lack of engine power is noted even after cleaning or element.
  • Page 116 TRANSMISSION OIL TRANSMISSION OIL .0~8.0 ton Do not touch hot components or allow hot oil Do not touch hot components or allow hot oil to contact your skin. to contact your skin. Dipstick (1) (1) Transmission oil Transmission oil Filter Park the truck in a level place and lower the forks.
  • Page 117 6) 6) HYDRAULIC TANK HYDRAULIC TANK (1) (1) Hydraulic oil change Hydraulic oil change Park the truck in a level place and lower the forks. Then stop the engine and apply the parking brake. Change oil after removing drain plug on tank bottom.
  • Page 118 7) 7) COOLING SYSTEM COOLING SYSTEM (1) (1) Radiator fins cleaning Radiator fins cleaning Remove dust between radiator fins with compressed air. Steam or water may be used instead of compressed air. Air pressure should be less than 200 kPa (30 psi). Nozzle of cleaning device should be held about 50 mm (2 in) from radiator fins.
  • Page 119 The tires and rims should always be serviced or changed by trained personal using the correct tools and procedures. For details of procedures, contact your HYUNDAI using the correct tools and procedures. For details of procedures, contact your HYUNDAI dealer.
  • Page 120 9) 9) FUSES REPLACEMENT FUSES REPLACEMENT ① ② ③ ④ ⑤ ⑥ ⑦ No. Capacity Color Related electrical component TAIL TURN CLUST- HORN HEAD BACK STOP LAMP ① LAMP LAMP Tail back lamp /OPSS ② Blue Head lamp SPARE (10A) SPARE (10A) SPARE (15A) ③...
  • Page 121 LAMP BULBS REPLACEMENT LAMP BULBS REPLACEMENT Lamp Spec (24V) Head lamp Turn signal lamp Clearance lamp Stop lamp Backup lamp Warning lamp 1.4W Meter lighting lamp 3.4W D507OM14 License lamp (option) Beacon lamp (option) Strobe type Rear work lamp After checking that the fuse is not blown and that there is no disconnection in the wiring After checking that the fuse is not blown and that there is no disconnection in the wiring harness, replace the lamp bulb.
  • Page 122 (4) (4) Service brakes and inching pedal Service brakes and inching pedal With the gear selector lever in NEUTRAL and the engine running, push the service brake pedal fully down and hold. The brakes should apply before the pedal reaches the floor plate. If the pedal continues to creep downward, report the failure immediately.
  • Page 123 (8) (8) Steering system Steering system ※ The steering system, steering axle, and steering linkage on your truck should be inspected 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 periodically for abnormal looseness and damage, leaking seals, etc..
  • Page 124 Inspect the battery for damage, cracks, leaking condition, etc.. If the terminals are corroded, clean and protect them with HYUNDAI battery saver (Available from your HYUNDAI dealer). If your battery has removable cell caps, check to be sure the cells are all filled. Refill them with distilled water.
  • Page 125 OIL PERFORMANCE DESIGNATION : To help achieve proper engine performance and durability, use only engine lubricating oils of the proper quality. For diesel engines, HYUNDAI recommends that you use motor oil that meets API CH4 and SAE 10W-30.
  • Page 126 Clean the fittings and lubricate the tilt cylinder rod end bushings (forward end) and both the base rod-end bushings (rear end). Clean and lubricate the mast trunnion bushings. (3) (3) Lift chains Lift chains Lubricate the entire length of the mast rail lift and carriage chains with HYUNDAI chain and cable lube. 7-30...
  • Page 127 AIR CLEANING AIR CLEANING Always maintain a lift truck in a clean condition. Do not allow dirt, dust, lint, or other contaminants to accumulate on the truck. Keep the truck free from leaking oil and grease. Wipe up all oil spills. Keep the controls and floorboards clean, dry, and safe.
  • Page 128 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 129: Lubrication Chart

    Engine oil API CH4 class or better ATF DEXRON III (50DS-7E : -#0021, 70DS-7E : -#0192) T/M oil SHELL DONAX TD (50DS-7E : #0022-, 60DS-7E : #0001-, 70DS-7E : #0193-) Gear oil SAE 80W-90/API GL-5 (DRY), MOBILFLUID 424 (WET) Hydraulic oil...

  • Page 130: Greasing Point

    9. GREASING POINT 9. GREASING POINT Lift chain(coated with engine oil) Steering axle Tilt cylinder Fork stopper Adjust bolt Pedal pin Mast support 50DS7EOM173 7-34...

  • Page 131: Handling Machine In Extremely Hot Places

    10. HANDLING MACHINE IN EXTREMELY HOT PLACES 10. HANDLING MACHINE IN EXTREMELY HOT PLACES Pay careful attention particularly to the following points when handling the machine in extremely hot places. ■ Cooling system Cooling system Scale and rust form more easily in the cooling system, so wash with anticorrosion liquid.

  • Page 132: Cold Weather Operation

    11. COLD WEATHER OPERATION 11. COLD WEATHER OPERATION 1) 1) PREPARATION FOR LOW TEMPERATURE 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 25 30 35 40 45 50 60 D975 No.1 diesel fuel should be used at...

  • Page 133: Storage

    12. STORAGE BEFORE STORAGE When you keep your forklift truck in storage for an extended period of time, observe the following safeguard instruction: 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 134: Transport

    PRECAUTIONS FOR LOADING AND UNLOADING PRECAUTIONS FOR LOADING AND UNLOADING Contact your HYUNDAI forklift distributor for advice regarding transportation of the machine. When loading or unloading the machine on or from a transporter, using loading ramp, the following precautions must always be observed.

  • Page 135: Loading And Unloading By Crane

    14. LOADING AND UNLOADING BY CRANE 14. LOADING AND UNLOADING BY CRANE Check the weight, length, width and height of the truck referring to the chapter 8, specifications Wire rope when you are going to hoist the truck. Stay Use long wire rope and stay to keep the distance Mast with the machine as it should avoid touching with the truck body.

  • Page 136: Recommendation Table For Lubricants

    SAE 10W-30 (API CH4 class or better) ATF DEXRON III (50DS-7E : -#0021, 70DS-7E : -#0192) T/M oil SHELL DONAX TD (50DS-7E : #0022-, 60DS-7E : #0001-, 70DS-7E : #0193-) Gear oil SAE 80W-90/API GL-5 (DRY), MOBILFLUID 424 (WET) Hydraulic oil ISO VG46/VG68, Hyundai genuine long life hydraulic oil ★1...

  • Page 137: Fuel And Lubricants

    (4.3) SAE 10W-30 SAE 15W-40 ATF DEXRON III Torque (50DS-7E:-#0021, 70DS-7E:-#0192) Transmission converter (4.8) transmission SHELL DONAX TD (50DS-7E:#0022-, 60DS-7E:#0001-, 70DS-7E:#0193-) 12.5 SAE 80W-90/API GL-5 (DRY), MOBILFLUID 424 (WET) Axle Gear oil (3.3) ★ ISO VG 15 Hydraulic Hydraulic tank (27.7)

  • Page 138: Specifications

    8. SPECIFICATIONS 8. SPECIFICATIONS 1. SPECIFICATION TABLE 1. SPECIFICATION TABLE 50DS7ESP01 Model Unit 50DS-7E 60DS-7E 70DS-7E Capacity 5000 6000 7000 ← ← Load center Weight (Unloaded) 8602 9245 9871 ← ← Lifting height 3030 ← ← Free lift Fork Lifting speed (Unload/Load)

  • Page 139: Specification For Major Components

    2. SPECIFICATION FOR MAJOR COMPONENTS 2. SPECIFICATION FOR MAJOR COMPONENTS 1) 1) ENGINE ENGINE Item Unit Specification Model MITSUBISHI S6S-T Type 4-cycle, in-line, Vertical OHV Cooling method Water cooling Number of cylinders and arrangement 6 cylinders, in line Firing order 1-5-3-6-2-4 Combustion chamber type Indirect injection...
  • Page 140 4) 4) POWER TRAIN DEVICES POWER TRAIN DEVICES Item Specification Model W280, 2.526/248 Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.526 Type Full auto, Power shift Gear shift (FWD/REV) Transmission Control Electrical single lever type 1st : 4.446 2nd : 2.341 3rd : 0.974 Overhaul ratio...

  • Page 141: Tightening Torque

    3. TIGHTENING TORQUE 3. TIGHTENING TORQUE Items Size kgf·m lbf·ft Engine mounting bolt, nut M16×2.0 Engine Radiator mounting bolt, nut M10×1.5 6.9±1.4 50±10 MCV mounting bolt, nut M12×1.75 12.8±3.0 93±22 Hydraulic system Steering unit mounting bolt M10×1.5 6.9±1.4 50±10 Transmission mounting bolt, nut M16×2.0 Torque converter mounting bolt M10×1.5...

  • Page 142: 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 143: 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 144: Torque Flow System

    3. TORQUE FLOW SYSTEM 3. TORQUE FLOW SYSTEM Trouble symptom Probable cause Remedy 1. Excessive oil 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 145 Trouble symptom Probable cause Remedy 3.Low output power 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 146 Trouble symptom Probable cause Remedy 4.Unusual oil pressure 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.
  • Page 147 Trouble symptom Probable cause Remedy ·Foreign matter intruding into oil pass- ·Disassemble, check and repair or 5. Power is not transmitted 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 148: 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 149: Brake System

    5. BRAKE SYSTEM 5. BRAKE SYSTEM Trouble symptom Trouble symptom Probable cause Probable cause Remedy Remedy ·Hydraulic system leaks oil. ·Repair and add oil. 1. Insufficient braking force ·Hydraulic system sucks air. ·Bleed air. ·Lining surface soiled with water or oil. ·Clean or replace.
  • Page 150 Trouble symptom Trouble symptom Probable cause Probable cause Remedy Remedy ·Lining poor contact with drum. ·Repair or replace. 5. Brake squeaks ·Anti-rattle spring poorly installed. ·Repair or replace. (continue) ·Drum sliding surface roughened. ·Repair by polishing or replace. 6. Brake rapping ·Drum eccentric or excessively distort- ·Replace.

  • Page 151: 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 152: 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 selector lever at N, and pull parking brake. Turn start switch ON. When heater signal lamp goes out, turn key to START, and start engine.
  • Page 153 4) 4) AIR CLEANER ELEMENT AIR CLEANER ELEMENT Blow dry compressed air (max 2 kgf/cm 30 psi) from inside along pleats. Next blow air from outside along pleats, then blow from inside again. Replace element if it is dirty, clogged or damaged.
  • Page 154 The fuel filter element 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 155 FAN BELT FAN BELT Check that fan belt is not damaged. Alt. pulley Check inside of belt also. If bottom of pulley pulley groove is shining, belt will slip so replace. Check deflection when fan belt is pushed with a finger pressure at a point midway between fan pulley and alternator pulley.

  • Page 156: Drive System

    2. DRIVE SYSTEM 2. DRIVE SYSTEM 1) 1) GEAR SELECTOR LEVER GEAR SELECTOR LEVER (1) (1) Neutral starting Neutral starting Engine can be started only when the forward-reverse lever is in neutral position. (2) (2) Shifting forward-reverse lever Shifting forward-reverse lever ①...
  • Page 157 (3) (3) Inching pedal Inching pedal ·Adjust stopper bolt (1) so that pedal height is "H". ·Adjust rod (2) so that length of inching spool is "A" when pedal height is "H". ·Adjust bolt (3) so that brake pedal interconnects with inching pedal at inching pedal stroke "P".
  • Page 158 (2) (2) Differential case Differential case Remove the dipstick at front face of the differential case. The oil should be leveled Filler plug with the marking on the dipstick. If the oil level is too low, add oil through the dipstick hole at the top of the differential case.

  • Page 159: Travel System

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

  • Page 160: Steering System

    4. STEERING SYSTEM 4. STEERING SYSTEM STEERING WHEEL STEERING WHEEL Set rear wheels facing straight forward, 30~60mm then turn steering wheel to left and right. (1.2~2.4 in) Measure range of steering wheel movement before rear wheel starts to move. Range should be 30~60 mm at rim of steering wheel.

  • Page 161: Adjustment Of Parking Brake Lever

    5. ADJUSTMENT OF PARKING BRAKE LEVER 5. ADJUSTMENT OF PARKING BRAKE LEVER 1. RATCHET TYPE PARKING LEVER 1. RATCHET TYPE PARKING LEVER Put the lever in the brake released position. Turn knob in order that the adjuster(2) may be operated. Knob The stroke of the parking lever is as follows.

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