Hyundai 50-7A Manual
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Hyundai 50-7A Manual

Hyundai 50-7A Manual

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1. Daily inspection ------------------------------------------------------------------------------------------------------------- 1-1
2. Do's and don'ts -------------------------------------------------------------------------------------------------------------- 1-2
3. Seat belts ----------------------------------------------------------------------------------------------------------------------- 1-4
4. No riders ------------------------------------------------------------------------------------------------------------------------- 1-5
5. Pedestrians -------------------------------------------------------------------------------------------------------------------- 1-6
6. Operator protection ------------------------------------------------------------------------------------------------------- 1-7
7. Fork safety ------------------------------------------------------------------------------------------------------------------ 1-8
8. Pinch points ---------------------------------------------------------------------------------------------------------------- 1-9
9. Travel ------------------------------------------------------------------------------------------------------------------------------ 1-10
10. Grades, ramps, slopes and inclines ---------------------------------------------------------------------------- 1-11
11. Tip over --------------------------------------------------------------------------------------------------------------------------- 1-12
12. Surface and capacity ---------------------------------------------------------------------------------------------------- 1-14
13. Parking --------------------------------------------------------------------------------------------------------------------------- 1-15
14. Refueling ------------------------------------------------------------------------------------------------------------------------ 1-16
15. Step -------------------------------------------------------------------------------------------------------------------------------- 1-17
16. Operator's safety rules -------------------------------------------------------------------------------------------------- 1-18
17. Side shift ------------------------------------------------------------------------------------------------------------------------ 1-19
1. Loose loads -------------------------------------------------------------------------------------------------------------------- 2-1
2. Long and wide loads ----------------------------------------------------------------------------------------------------- 2-2
3. Rear swing --------------------------------------------------------------------------------------------------------------------- 2-2
4. Low overhead clearance ----------------------------------------------------------------------------------------------- 2-3
5. Fast turns and high loads ---------------------------------------------------------------------------------------------- 2-3
6. Right angle stacking ------------------------------------------------------------------------------------------------------ 2-4
7. Chain slack --------------------------------------------------------------------------------------------------------------------- 2-4
8. Pallets and skids ------------------------------------------------------------------------------------------------------------ 2-5
9. Caution for electrical lines --------------------------------------------------------------------------------------------- 2-5
10. Lifting loads -------------------------------------------------------------------------------------------------------------------- 2-6
11. Side shift ------------------------------------------------------------------------------------------------------------------------- 2-6
12. Fork positioner --------------------------------------------------------------------------------------------------------------- 2-8
CONTENTS
CONTENTS

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Summary of Contents for Hyundai 50-7A

  • Page 1: Table Of Contents

    CONTENTS CONTENTS 1. SAFETY HINTS 1. SAFETY HINTS 1. Daily inspection ------------------------------------------------------------------------------------------------------------- 1-1 2. Do's and don'ts -------------------------------------------------------------------------------------------------------------- 1-2 3. Seat belts ----------------------------------------------------------------------------------------------------------------------- 1-4 4. No riders ------------------------------------------------------------------------------------------------------------------------- 1-5 5. Pedestrians -------------------------------------------------------------------------------------------------------------------- 1-6 6. Operator protection ------------------------------------------------------------------------------------------------------- 1-7 7. Fork safety ------------------------------------------------------------------------------------------------------------------ 1-8 8.
  • Page 2 3. KNOW YOUR TRUCK 3. KNOW YOUR TRUCK 1. General locations ----------------------------------------------------------------------------------------------------------- 3-1 2. Data/safety plate and decal ------------------------------------------------------------------------------------------ 3-2 3. Cab devices ------------------------------------------------------------------------------------------------------------------- 3-4 4. Cluster ---------------------------------------------------------------------------------------------------------------------------- 3-5 5. Transmission message indicator --------------------------------------------------------------------------------- 3-16 6. Switches & lamps ---------------------------------------------------------------------------------------------------------- 3-21 7.
  • Page 3 7. PLANNED MAINTENANCE AND LUBRICATION 7. PLANNED MAINTENANCE AND LUBRICATION 1. Introduction -------------------------------------------------------------------------------------------------------------------- 7-1 2. Safe maintenance practices ---------------------------------------------------------------------------------------- 7-2 3. Instructions before maintenance --------------------------------------------------------------------------------- 7-5 4. Planned maintenance intervals ----------------------------------------------------------------------------------- 7-8 5. Maintenance chart -------------------------------------------------------------------------------------------------------- 7-12 6. How to perform planned maintenance ----------------------------------------------------------------------- 7-15 7.
  • Page 4 HYUNDAI lift trucks are built to take hard work, but not abuse. They are built to be dependable, but they are only as safe and efficient as the operator and the persons responsible for maintaining them. Do not make any repairs to this truck unless you have been trained in safe lift truck repair procedures and are authorized by your employer.
  • Page 5 HYUNDAI lift truck in a safe and correct manner. Your HYUNDAI lift truck has been designed and built to be as safe and efficient as today's technology can make it. As manufactured, for some models, it meets all the applicable mandatory requirements of ANSI B56.1-1988 Safety Standard for Powered Industrial Trucks.
  • Page 6 The descriptions and specifications included in this manual were in effect at the time of printing. HYUNDAI reserves the right to make improvements and changes in specifications or design, without notice and without incurring obligation. Please check with your authorized HYUNDAI dealer for information on possible updates or revisions.
  • Page 7 Acquaint yourself with the various procedures in this manual. Understand how all gauges, indicator lights, and controls function. Please contact your authorized HYUNDAI dealer for the answers to any questions you may have about your lift truck's features, operation, or manuals.
  • Page 8 EC REGULATION APPROVED EC REGULATION APPROVED · Noise level (2000/14/EC and EN 12053) are as followings. Model (EU only) 50/60/70D-7A 105 dB 76.8 dB · The value of vibrations transmitted by the operator's seat are lower than standard value of (2002/44/...

  • Page 9: Safety Labels

    SAFETY LABELS SAFETY LABELS 1. LOCATION 1. LOCATION Always keep these labels clean. If they are lost or damaged, attach them again or replace them with a new label. DASH BOARD COVER FAN SHROUD RCV LEVER PARKING BRAKE 22 18 5 50D7AOM101 Logo 11 Operator safety...
  • Page 10 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) MAST WARNING MAST WARNING (ltem 2) This warning label is positioned on the left side of the mast.

  • Page 11: Tire Pressure

    HAND CAUTION HAND CAUTION (Item 3) This warning label is positioned on the top side of mast. It warns of the danger of injury from It warns of the danger of injury from m o v e m e n t b e t w e e n r a i l s , c h a i n s , m o v e m e n t b e t w e e n r a i l s , c h a i n s , sheaves, fork carriage, and other parts of sheaves, fork carriage, and other parts of...

  • Page 12: Parking Brake

    START WARNING START WARNING (Item 12) This warning label is positioned on the middle side of dashboard cover. 5 6’ ※ Start key switch after 5~6 seconds from Start key switch after 5~6 seconds from 92AD-00920 O N p o s i t i o n . I t n e e d s a p p r o x 5 ~ 6 O N p o s i t i o n .
  • Page 13 9) 9) SAFETY INSTRUCTION SAFETY INSTRUCTION (Item 19) Truck for USA or travel * OPSS This warning label is positioned on the inside of cabin door if the truck is for equipped with *OPSS. This forklift is equipped with an operator This forklift is equipped with an operator existence sensing system per ANSI/ existence sensing system per ANSI/...

  • Page 14: Operator Safety

    OPERATOR SAFETY OPERATOR SAFETY (Item 11) This warning label is positioned on the inside of LH cabin door. 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 15 TILT CABIN WARNING TILT CABIN WARNING (Item 34) This warning label is positioned on the lift side of frame. When tilting cab for service, the cab MUST BE FULLY EXTENDED UP or DOWN. To raise cab, depress switch down until fully raised.

  • Page 16: Engine Serial Number

    GUIDE GUIDE 1. DIRECTION 1. DIRECTION The directions of this truck indicate forward, Front backward, right and left when truck is in the travelling direction. Left Right Rear 50D7ASM01 2. SERIAL NUMBER 2. SERIAL NUMBER Inform following when you order parts or the truck is out of order. 1) 1) TRUCK SERIAL NUMBER TRUCK SERIAL NUMBER...

  • Page 17: Safety Hints

    1. SAFETY HINTS 1. SAFETY HINTS 1. DAILY INSPECTION 1. DAILY INSPECTION At the beginning of each shift, inspect your truck and fill out a check, maintenance and lubrication table. Check for damage and maintenance problems. Have repairs made before you operate the truck. Do not make repairs yourself.

  • Page 18: Do's And Don'ts

    2. DO'S AND DON'TS 2. DO'S AND DON'TS Do watch for pedestrians. D35AOM03 Do wear safety equipment when required. D35AOM05 Don't mix drugs or alcohol with your job. D35AOM02 Don't block safety or emergency equipment. 160D7OM04 Don't smoke in NO SMOKING areas or when refueling. D35AOM06...
  • Page 19 Don't operate the truck outdoors in rainy day. ※Exclude the truck equipped cabin. Exclude the truck equipped cabin. 50D7AOM07 Exhaust gas is dangerous. Do not operate the truck at the inhouse, if possible. Provide adequate ventilation when working in a closed space. 50D7AOM08...

  • Page 20: Seat Belts

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

  • Page 21: No Riders

    4. NO RIDERS 4. NO RIDERS The operator is the only one who should be on a truck. 50D7AOM12 Never transport personnel on the forks of a lift truck. 50D7AOM14...

  • Page 22: Pedestrians

    5. PEDESTRIANS 5. PEDESTRIANS Watch where you are going. Look in the direction of travel. Pedestrians may use the same roadway you do. Sound your horn at all intersections or blind spots. 50D7AOM05 Watch for people in your work area even if your truck has warning lights or alarms.

  • Page 23: Operator Protection

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

  • Page 24: Fork Safety

    7. FORK SAFETY 7. FORK SAFETY Never allow anyone to walk under raised forks. D255OM17A There is special equipment to raise people for overhead work. DO NOT USE LIFT TRUCKS. 50D7AOM14 Always lower the load slowly. Raise and lower with mast vertical or tilted slightly back(Never forward).

  • Page 25: Pinch Points

    8. PINCH POINTS 8. PINCH POINTS Keep hands, feet and legs out of the Keep hands, feet and legs out of the mast. mast. D255OM61 Don't use the mast as a ladder. Don't use the mast as a ladder. 50D7AOM62 Never try to repair the mast, carriage, Never try to repair the mast, carriage, chain, or attachment by yourself.

  • Page 26: Travel

    9. TRAVEL 9. TRAVEL Travel with the load near the floor/ground, with mast tilted back to cradle the load whenever possible. Never lift or lower the load when the Never lift or lower the load when the truck is in motion. truck is in motion.

  • Page 27: Grades, Ramps, Slopes And Inclines

    10. GRADES, RAMPS, SLOPES AND INCLINES 10. GRADES, RAMPS, SLOPES AND INCLINES Never turn on a grade, either loaded or unloaded. Never turn on a grade, either loaded or unloaded. Unloaded-Forks downgrade 50D7AOM30 Loaded - Forks upgrade 50D7AOM33 1-11...

  • Page 28: Tip Over

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

  • Page 30: Surface And Capacity

    12. SURFACE AND CAPACITY 12. SURFACE AND CAPACITY Avoid these conditions. They can cause a truck to tip over or lose traction for braking or driving. Know the weight of your truck and load. Know the weight of your truck and load. Especially when using elevators, Know Especially when using elevators, Know the capacity of the elevator you intend to...

  • Page 31: Parking

    13. PARKING 13. PARKING Never park on a grade. 50D7AOM41 Always come to a complete stop before leaving truck. Be sure travel control is in NEUTRAL. 50D7AOM42 Lower forks fully to floor and tilt forward. 50D7AOM44 Set parking brake. Position 1 : OFF(Release) Position 2 : ON(Lock) Turn key to OFF position.

  • Page 32: Refueling

    14. REFUELING 14. REFUELING Before adding oil, check around truck for oil leakage. 50D7AOM47 Keep away from fire when adding oil or during operation. 50D7AOM48 After adding oil, wipe off any oil spilled on truck. 50D7AOM49 1-16...

  • Page 33: Step

    15. STEP 15. STEP When getting on or off the truck, use the step provided. 50D7AOM50 Do not jump up or down from the truck. 50D7AOM52 1-17...

  • Page 34: Operator's Safety Rules

    16. OPERATOR'S SAFETY RULES 16. OPERATOR'S SAFETY RULES All operational functions require that the operator be seated in the operator's seat. Always buckle up if a seat belt is Always buckle up if a seat belt is provided. provided. 50D7AOM18 Parking brake must be locked in the PARK POSITION before exiting from the vehicle.

  • Page 35: Side Shift

    17. SIDE SHIFT SIDE SHIFT Do not put side loads on forks. Do not put side loads on forks. 50D7A1SS01 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 36: Operating Hazards

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

  • Page 37: Long And Wide Loads

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

  • Page 38: Low Overhead Clearance

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

  • Page 39: Right Angle Stacking

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

  • Page 40: Pallets And Skids

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

  • Page 41: Lifting Loads

    10. LIFTING LOADS 10. LIFTING LOADS Never permit any persons to stand or pass under lifted load. 50D7AOM58 Never use wire rope to lift a load. 50D7AOM60 11. SIDE SHIFT 11. SIDE SHIFT Never operate the side shift while the forks are not equipped with supports such as a load table for the load.
  • Page 42 It should be observed that the side shift with load is operated in netural position before traveling. When operating side shift with load, operate slowly so that it can not avoid from dropping of the load or overturning of the fork lift.

  • Page 43: Fork Positioner

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

  • Page 44: Know Your Truck

    3. KNOW YOUR TRUCK 1. GENERAL LOCATIONS 50D7AOM54 Mast Cabin 13 Counterweight Lift chain Turn signal lamp 14 Rear wheel Lift cylinder Head lamp 15 Front wheel Carriage & backrest 10 Rear work lamp 16 Rear combination lamp Tilt cylinder 11 Operator's seat Forks 12 Bonnet...

  • Page 45: Data/Safety Plate And Decal

    Truck serial number An identification number assigned to this particular truck and should be used when requesting information or ordering service parts for this truck from your authorized HYUNDAI dealer. The serial number is also stamped on the frame. Attachment description (If any installed) The user must see that the truck is marked to identify the attachment (s), including the weight of the truck/attachment combination and truck capacity with the attachment.
  • Page 46 OPERATOR SAFETY WARNING DECAL 250D7EOM59 Safety and warning decals are placed in conspicuous locations on the truck to remind you of essential procedures or to prevent you from making an error that could damage the truck or possibly cause personal injury. You should know, understand, and follow these instructions.

  • Page 47: Cab Devices

    3. CAB DEVICES The ergonomically designed console box and suspension type seat provide the operator with comfort. ELECTRONIC MONITOR SYSTEM The centralized electronic monitor system allows the status and conditions of the truck to be monitored at a glance. It is equipped with a safety warning system for early detection of truck malfunction. 50D7ACD01...

  • Page 48: Cluster

    4. CLUSTER STRUCTURE The gauges panel consists of gauges and monitors as shown below, to warn the operator in case of abnormal truck operation or conditions for the appropriate operation and inspection. Gauges : Indicate operating status of the truck. Warning lamp : Indicate abnormality of the truck.
  • Page 49 GAUGE Speed meter The speedmeter displays the speed of truck in mph and km/h. 7807A3CD03 Fuel gauge This gauge indicates the amount of fuel in the fuel tank. Fill the fuel when the indicator moves E point, refuel as soon as possible to avoid running out of fuel.

  • Page 50: Warning Lamps

    WARNING LAMPS 50D9CD02-1 Engine check lamp This lamp light ON during a nonfatal engine system error. The engine can still be run, but the fault should be corrected as soon as possible. 160D7ECD904 Brake fail warning lamp The lamp lights ON when the oil pressure of service brake drops below the normal range.
  • Page 51 Engine oil pressure warning lamp This lamp comes ON for a while after starting the engine because of the low oil pressure. If the lamp comes ON during engine operation, shut OFF engine immediately. Check oil level. 77073CD18 Air cleaner warning lamp This lamp operates by the vacuum caused inside when the filter of air cleaner is clogged.
  • Page 52 Seat belt warning lamp This lamp lights ON for the first five seconds after starting the truck. 77073CD24 Engine coolant temperature warning lamp This lamp is turned ON when the temperature of cooling water is over the normal temperature(104 C, 219 F). Check the cooling system when the lamp is ON.
  • Page 53 (13) OPSS warning 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. Transmission will automatically shift to neutral upon the exiting of the operator. The forward/reverse lever must be cycled through neutral with 160D7ECD14 the operator in the normal operating position to regain powered...

  • Page 54: Pilot Lamps

    PILOT LAMPS 50D9CD02-2 Direction pilot lamp This lamp flashes when the signal indicator lever is moved. 77073CD10 Work lamp pilot lamp (rear) This lamp lights ON when rear work lamp switch is pressed. 77073CD11 3-11 3-11...
  • Page 55 Head light pilot lamp This lamp comes ON when the main light switch is operated to 2nd step. 160D7CD07 Preheater pilot lamp This lamp lights ON when start switch is turned clockwise to the ON position. Light will turn off after approximately 15~45 seconds, depending on engine coolant coolant temperature, indicating that preheating is completed.
  • Page 56 CLUSTER BUTTON Each button has the following function. 160D7ECD121E Buzzer stop button This button is used to stop the buzzer sound. If another alarm condition occurs after this button has been pressed, the alarm buzzer will re-sound. 160D7ECD22 Menu button To select engine error display mode, press this button.
  • Page 57 Menu and next buttons These buttons are used to select the model select mode. The initial model is selected at the factory, so don't change the different model. 80D9CD200/201 3-14...
  • Page 58 LCD has the functions to display start mode, standby mode, engine error display etc. Name and display Description Start mode - Displays initialization state with HYUNDAI logo and program version. Standby mode Displays on the idle state. Displays engine speed, odometer and hourmeter.

  • Page 59: Transmission Message Indicator

    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. 3-16...
  • Page 60 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 61 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 62 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 63 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 64: Switches & Lamps

    6. SWITCHES & LAMPS 50D7ACD05 START SWITCH There are three positions, OFF, ON and START. (OFF) : None of electrical circuits activate. (ON) : All the systems of truck operate. (START) : Use when starting the engine. Release key immediately after starting. 77073CD41 3-21...

  • Page 65: Work Lamp Switch

    HAZARD SWITCH (OPTION) Use for parking, or loading truck. If the switch is left ON for a long time, the battery may be discharged. 160D7CD42 INCHING SWITCH If this switch is pressed, inching operation is applied to inching pedal. Also, inching lamp on the cluster is illuminated. 160D7CD43 MAIN LIGHT SWITCH This switch is used to operate the head light by one steps.
  • Page 66 AUTO/MANUAL CHANGEOVER SWITCH Manual mode ( ) Press the top of the switch for the manual mode of the autoshift function. The operator selects the desired speed and the desired direction in the manual mode with the gear selector lever. Automatic 1st mode ( ) Place the switch in the middle position for the autoshift function 160D7CD49...

  • Page 67: Horn Button

    BEACON SWITCH (OPTION) This switch turn ON the strobe light. L255OM18 HORN BUTTON If you press the button on the top of the multifunction switch and the center of the steering wheel, the horn will sound. 160D7ECD28 CAB LAMP SWITCH This switch turns ON the cab room lamp.
  • Page 68 ENGINE STOP LAMP If the lamp lights ON, stop the engine immediately and check the engine. Please contact your Hyundai service center or local dealer. 35D9ACL006 PARKED REGENERATION REQUEST LAMP This warning lamp lights ON or blink when the regeneration is needed as next page.
  • Page 69 REGENERATION LAMP This warning lamp lights ON or blinks during the regeneration is operating. 35D9ACL002 DPF lamp sequence recommended Inhibit Parked regeneration Regeneration lamp switch state request lamp Description Normal operation Blinking (Regeneration not requested) Parked regeneration needed Blinking Blinking Parked regeneration occurring Blinking Solid lighting...
  • Page 70 Parked regeneration method of DPF Parked regeneration applies if the machine is in a fireproof area and there is no plan to turn off the maching during the regeneration. Stop and park the machine. Put the gear in neutral position and wait until coolant temperature reaches 65˚C.

  • Page 71: Regeneration System

    7. REGENERATION SYSTEM Regeneration Particulate matter (mainly soot) filtered in DPF (diesel particulate filter) occurs poor performance caused by increasing exhaust gas pressure, incinerating process to convert from accumulated soot to ash is required. This process named regeneration. The type of regeneration composes of automatic regeneration (active, auto-play by exhaust gas heat) and parked regeneration (passive play by the artificial aid).

  • Page 72: Control Device

    8. CONTROL DEVICE 50D7ACD08 LIFT LEVER LIFT PULL the lever BACK to LIFT the forks. LOWER PUSH the lever FORWARD to LOWER the load. HOLDING When the lever is released, the lifting or lowering action stops. 160D7CD12 Lifting speed is controlled by accelerator pedal. Lowering speed is controlled by lever only.
  • Page 73 LEVER FOR SIDE SHIFT LH MOVEMENT Push the lever forward to move the left hand for the side shift. RH MOVEMENT Pull the lever backward to move the right hand for the side shift. 160D7CD17 LEVER FOR SIDE SHIFT WITH FORK POSITIONER FORK POSITIONER (SYNCHRONIZER TYPE) OUTSTRECH THE FORKS Push the lever forward to outstrech simultaneously outward of the...

  • Page 74: Gear Selector Lever

    RH FORK MOVEMENT - Push the lever forward to move outward for the RH fork. - Pull the lever backward to move inward for the RH fork. 160D7CD22 GEAR SELECTOR LEVER This lever is used for gear selection, forward 3 stages and reverse 3 stages.

  • Page 75: Accelerator Pedal

    ACCELERATOR PEDAL This pedal controls the engine speed. The engine speed will increase in proportion to the degree of force applied to this pedal. Unless this pedal is pressed, the truck will run at low idling. 160D7ECD32 INCHING PEDAL Inching pedal is used for fine control of forward and reverse movement when lifting up or putting down loads.

  • Page 76: Air Conditioner And Heater

    9. AIR CONDITIONER AND HEATER Air conditioner and heater are equipped for pleasant operation against outside temperature and defrost on window glass. 50D7ACD90 FAN SPEED CONTROL SWITCH It is possible to control the fan speed to four steps. Fan speed 1 Fan speed 2 Fan speed 3 Fan speed 4...

  • Page 77: Temperature Control Switch

    OUTLET CONTROL SWITCH There are three steps of air flow. Front Front & defrost Defrost 50DECD51 TEMPERATURE CONTROL SWITCH This switch regulates the temperature of air. Right side (blue zone) : Cool down air temperature Left side (red zone) : Heat up air temperature 50D7ECD53 INLET CONTROL SWITCH This switch regulates the inlet air.

  • Page 78: Others

    10. OTHERS 50D7ACD09 CIGAR LIGHTER This can be used when the engine starting switch is ON. The lighter can be used when it springs out in a short while after being pressed down. Service socket 73033CD49 Use cigar lighter socket when you need emergency power. Do not use the lighter exceeding 24V, 100W.

  • Page 79: Monitor (Option)

    MONITOR (OPTION) Adjusting the angle Upwards and downwards up to 7˚ total 14˚. Swivels left and right up to 15˚ total 30˚. 110D7ECD100E Power button To turn the power off or on. To switch the monitor on or off, press and hold the power button for two second.
  • Page 80 Name Description Starting animation Main screen Load indicator Load indicator Camera selection To enter camera screen, press the button. To return to menu selection screen, press button. If you turn "Reverse Mode" on, camera view be shown at reverse or neutral gear. - Reverse : camera 1 - Neutral : camera 2 3-50...
  • Page 81 Name Description Display set up screen LCD brightness To adjust to display brightness, press to decrease or increase. Language selection Set a Korean or English. Unit setting Set a unit load indicator. 3-51...
  • Page 82 Name Description Mode set up screen 1)Option Load indicator Display the conditions for load indicator. Applied to the main screen, check the page 3-53. When you choose 'Load Indicator ON', you can pick O N / O F F o f o v e r w e i g h t buzzer.
  • Page 83 Name Description Mode set up screen 3)Load indicator setting MAST Select Equipment model selection varies depending on the mast. Calibration Correct a fork-lift load indicator After input passwords, you must input *. D e f i n e p a s s w o r d i s : "00008282"...
  • Page 84 Name Description Mode set up screen Weight correction Input a password Loaded enter the weight. (Input ton) In the loaded from the around waiting 5 seconds after lift 30 cm Weight correction ON 3-54...
  • Page 85 Name Description Mode set up screen 4)Maintenance Change the replacement cycle of expandable supplies. Using button for changing the replacement cycle. 3-55...
  • Page 86 Name Description Mode set up screen Service Contact Check and change of contact information for customer service. 3-56...
  • Page 87 Name Description Mode set up screen RMCU communication When successfully opened RMCU communication, except for the RMCU communication. 3-57...
  • Page 88 Name Description Mode set up screen 7)Camera select Gear linkage mode If you turn “Reverse mode” on, camera view be shown at reverse or neutral gear on main. - Reverse : camera 1 - Neutral : camera 2 Operation CAM set Set the number of operation camera.
  • Page 89 Name Description Ending animation 3-59...

  • Page 90: 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 91: Functional Checks

    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 92: 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 Service meter Load initial 100 hours...

  • Page 93: Fuel Safety Practices

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

  • Page 94: 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 95: Check Before Operation

    2. CHECK BEFORE OPERATION 2. CHECK BEFORE OPERATION The Occupational Safety and Health Act (OSHA) required that truck users examine their trucks before each shifts to be sure they are in safe working order. Defects when found shall be immediately reported and corrected. The truck shall be taken out of service until it has been restored to safe operating condition.

  • Page 96: Check Before Starting Engine

    CHECK FOR WATER OR OIL LEAKAGE CHECK FOR WATER OR OIL LEAKAGE Walk around your HYUNDAI truck and check for water, oil or hydraulic leakage. Examine truck for obvious damage. Check cabin, backrest and forks for crack or obvious damage.

  • Page 97: Check Coolant Level

    3) 3) CHECK COOLANT LEVEL CHECK COOLANT LEVEL If the cooling water in the radiator sub-tank is not within normal range when cool, add water to the MAX line. L255OM61 In antifreeze is being used, pay careful attention to the ratio of antifreeze and water when In antifreeze is being used, pay careful attention to the ratio of antifreeze and water when adding coolant.

  • Page 98: Check Battery

    5) 5) CHECK FAN BELT TENSION CHECK FAN BELT TENSION Cooling fan belt tensioner Maintenance check With the engine turned off, check that neither the top nor bottom tensioner arm stop is touching the cast boss on the tensioner body. If either of the stops is touching a boss, the 7807AMI50 alternator belt must be replaced.
  • Page 99 8) 8) CHECK WATER SEPARATOR CHECK WATER SEPARATOR WIF (Water in fuel) warning lamp. If the warning lamp stays on, drain the water from the fuel filter. 160D7CD15 When the float of separator meets the red line (drain level), drain water. Drain Float level...

  • Page 100: Seat Adjustment

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

  • Page 101: Starting From A Safe Condition

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

  • Page 102: General Starting And Operating Tips

    6. GENERAL STARTING AND OPERATING TIPS 6. GENERAL STARTING AND OPERATING TIPS Before you start the truck, make sure that you have taken all the above-mentioned precautions, you have read this manual, you are starting from a safe condition, with the directional control in NEUTRAL, the seat adjusted, and your seat belt buckled.

  • Page 103: Starting And Stopping The Engine

    7. STARTING AND STOPPING THE ENGINE 7. STARTING AND STOPPING THE ENGINE 1) 1) CHECK INDICATOR LIGHTS CHECK INDICATOR LIGHTS Gear selector lever Check if parking lever is LOCK position. Check if gear selector lever is in neutral position. Turn the key to the ON position, and check following.
  • Page 104 3) 3) STARTING ENGINE IN A COLD WEATHER STARTING ENGINE IN A COLD WEATHER ※ Sound horn to warn surroundings after Sound horn to warn surroundings after checking if there are obstacles in the area. checking if there are obstacles in the area. ※...
  • Page 105 Check engine exhaust color. Exhaust gas color Criteria Colorless, light blue Black Check for incomplete combustion White Check for oil leakage Check fuel tank level. If the indicator points to F, the tank is full. If the indicator enters the E range, refill the fuel tank immediately. Do not operate the truck below this level.

  • Page 106: To Stop The Engine

    (10) Check steering wheel. Check that steering wheel does not wobble or suddenly pull to one side. Check also for any abnormal heaviness in steering. (11) Check rear view mirror. Adjust the rearview mirror for best rearward visibility. TRANSMISSION COLD STARTING TRANSMISSION COLD STARTING At an oil temperature in the shifting circuit <...

  • Page 107: Warming-Up Operation

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

  • Page 108: 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 109 2) 2) SELECTING DIRECTION OF TRAVEL SELECTING DIRECTION OF TRAVEL Push the direction control lever forward, center it , or pull it back Forward for FORWARD, NEUTRAL, or REVERSE, respectively. Traction is disabled in NEUTRAL. Reverse 160D7OM95 3) 3) USING THE ACCELERATOR PEDAL USING THE ACCELERATOR PEDAL With the parking brake released and the direction control in FORWARD or REVERSE, put your foot on the accelerator...

  • Page 110: Traveling Of The Truck

    10. TRAVELING OF THE TRUCK 10. TRAVELING OF THE TRUCK 1) 1) BASIC OPERATION BASIC OPERATION Tilt back fully (1) (1) Traveling posture Traveling posture Lift the forks so that the forks are placed 15~ 20 cm (6~8 in) above the ground and tilt back the mast fully.
  • Page 111 ※ When traveling at high speed, do not When traveling at high speed, do not abruptly decelerate by using the trans- abruptly decelerate by using the trans- mission lever, to slow down instead press the mission lever, to slow down instead press the brake pedal.
  • Page 112 Stopping the truck Stopping the truck (6) (6) ① Press the brake pedal to stop the truck. Gear selector lever ② Put the gear selector lever in the neutral position. ③ Put the parking lever to LOCK position. Parking lever 50D7AOP14 ④...
  • Page 113 (7) (7) Stopping engine Stopping engine ear selector lever ※ If the engine is abruptly stopped before it has If the engine is abruptly stopped before it has c o o l e d d o w n , i t s s e r v i c e l i f e m a y b e c o o l e d d o w n , i t s s e r v i c e l i f e m a y b e shortened.

  • Page 114: Operating Safely

    11. OPERATING SAFELY 11. OPERATING SAFELY Safe operation is the responsibility of the operator. WATCH WHERE YOU ARE GOING. DON’T GO IF YOU CAN’T SEE... WATCH WHERE YOU ARE GOING. DON’T GO IF YOU CAN’T SEE... 1) 1) Before driving, check all around to be sure that your intended path of travel is clear of obstructions and pedestrians.
  • Page 115 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 116: Load Handling

    12. LOAD HANDLING 12. LOAD HANDLING 1) 1) GENERAL GENERAL Handle only loads that are within the truck rated capacity as shown on the nameplate. This rating specifies the maximum load that should be lifted. However, other factors such as special load handling attachments, load having a high center of gravity, or uneven terrain may dictate that the safe working load be less than the rated capacity.
  • Page 117 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 118 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 119 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 120 7) 7) STACKING STACKING To put a load on a stack To put a load on a stack (1) (1) ① Aproach slowly and align the lift truck and load squarely with the stack. D35AOM137 ② Raise the load as the lift truck nears the stack. D35AOM138 ③...
  • Page 121 (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 122: Shut Down Procedure

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

  • Page 123: Storage

    14. 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 124: Transport

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

  • Page 125: Loading And Unloading By Crane

    16. LOADING AND UNLOADING BY CRANE 16. LOADING AND UNLOADING BY CRANE Check the weight, length, width and height of the truck referring to the chapter 8, specifications when you are going to hoist the truck. Stay Wire rope Use long wire rope and stay to keep the distance with the machine as it should avoid touching with To lift bracket the truck body.

  • Page 126: 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 127 Park the disabled truck in authorized areas only. Fully lower the forks to the floor, put the directional control lever in the NEUTRAL position and turn the staring switch to the OFF position. Turn on the parking brake switch. Remove the key and, when necessary, block the wheels to prevent the truck from rolling.

  • Page 128: 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 24V negative-ground electrical system. The "Booster" battery must be fully charged and in good condition.
  • Page 129 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 130: Planned Maintenance And Lubrication

    Specifications for selected components, fuel, lubricants, critical bolt torques, refill capacities, and settings for the truck and found in section 9. If you have needed for more information on the care and repair of your truck, see your HYUNDAI dealer.

  • Page 131: 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 132 Before leaving the truck. Stop the truck. Fully lower the load-engaging means: mast, carriage, forks or attachments. Put the directional control in NEUTRAL. Apply the parking brake. Stop the engine. Turn the key switch to the OFF position. Put blocks at the wheels if the truck must be left on an incline. Brakes, steering mechanisms, control mechanisms, warning devices, lights, governors, lift overload devices, lift and tilt mechanisms, articulating axle stops, load backrest, CAB and frame members must be carefully and regularly inspected and maintained in a safe operating condition.
  • Page 133 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 134: 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 area, quarry, sea shore and etc.) Practice the entire related details at the same...

  • Page 135: Proper Maintenance

    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 136 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 recommended replacement interval.

  • Page 137: Planned Maintenance Intervals

    4. PLANNED MAINTENANCE INTERVALS 4. PLANNED MAINTENANCE INTERVALS 1) 1) MAJOR COMPONENTS LOCATION MAJOR COMPONENTS LOCATION 15 12 14 9 10 11 50D7AOM21 Mast Transmission 17 Counterweight Lift cylinder 10 Torque converter 18 Radiator Steering unit 11 Engine 19 Seat Tilt cylinder 12 Steering cylinder 20 Cabin...
  • Page 138 2) 2) MAINTENANCE CHECK LIST MAINTENANCE CHECK LIST (1) (1) EVERY 10 HOURS SERVICE EVERY 10 HOURS SERVICE Check items Service Remarks Visual inspection ·Truck for obvious damage and leaks. Check, Repair or Replace 7-15 ·Warning plates and decals. Check, Replace 7-15 ·Condition of tires and wheels.

  • Page 139: Every 250 Hours Service

    INITIAL 50 HOURS SERVICE INITIAL 50 HOURS SERVICE Check items Service Remarks Engine oil Change 7-20 Engine oil filter Replace 7-20 Pilot line filter element Replace 7-34 INITIAL 100 HOURS SERVICE INITIAL 100 HOURS SERVICE Check items Service Remarks Transmission oil and filter Replace 7-38 Differential gear oil...
  • Page 140 EVERY 3000 HOURS SERVICE EVERY 3000 HOURS SERVICE Check items Service Remarks DPF muffler Clean 7-32 (11) (11) EVERY 5000 HOURS SERVICE EVERY 5000 HOURS SERVICE Check items Service Remarks Replace 7-33 Hydraulic oil (* Hyundai genuine long life hydraulic oil 7-11...

  • Page 141: When Required

    (12) (12) WHEN REQUIRED WHEN REQUIRED Check items Service Remarks Fuel system ·Fuel tank 7-28 Drain or Clean ·Water separator 7-28 Drain or Clean ·Fuel filter 7-29 Replace Engine lubrication system ·Engine oil 7-20 Replace ·Engine oil filter cartrige 7-20 Replace Engine cooling system ·Coolant...

  • Page 142: Maintenance Chart

    5. MAINTENANCE CHART 5. MAINTENANCE CHART 1) 1) MAINTENANCE LOCATIONS MAINTENANCE LOCATIONS 50D7AMA011 CAUTION CAUTION ※ Service intervals are based on the hourmeter reading. ※ Stop the engine when servicing. ※ Do not open the cap or drain plug to avoid injury by unexpected spouting of high temperature fluid or gas.
  • Page 143 Change 3000 Hours 30 DPF muffler Clean 5000 Hours 21 Hydraulic oil Change Conventional hydraulic oil Hyundai genuine long life hydraulic oil ※ Oil symbol Refer to the recommended lubricants for specification. DF : Diesel fuel HO : Hydraulic oil...

  • Page 144: 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 145 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 and even with each other. The height difference max. wear allowed between both fork tips refer to below table. Fork length Height Model...

  • Page 146: Wheel And Tires

    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 147 7) 7) TILTING CABIN TILTING CABIN Keep clearance of people except the operator Keep clearance of people except the operator before tilting the cabin. before tilting the cabin. Before tilting the cabin, make sure that the Before tilting the cabin, make sure that the mast is vertical or tilted forward.
  • Page 148 Do not operate cabin tilting function while the Do not operate cabin tilting function while the power is ON or engine is running. It can cause power is ON or engine is running. It can cause severe injury or death. severe injury or death.

  • Page 149: Service Instruction

    7. SERVICE INSTRUCTION 7. SERVICE INSTRUCTION 1) 1) CHECK OF ENGINE OIL LEVEL CHECK OF ENGINE OIL LEVEL Make the engine level. Pull out the dipstick (1) and clean it. Put in and pull it out again. Make sure that the oil level is between the 2 notches.
  • Page 150 2) 2) CHANGE OF ENGINE OIL CHANGE OF ENGINE OIL Make sure that you stop the engine Make sure that you stop the engine before you change the engine oil. before you change the engine oil. Start and warm-up the engine for approximately 5 minutes.
  • Page 151 4) 4) CHECK COOLANT LEVEL CHECK COOLANT LEVEL Check the coolant level at reservoir tank. Add the mixture of antifreeze and water after if coolant is not sufficient. The coolant level should indicate the middle position. Replace gasket of radiator cap when it is damaged.
  • Page 152 Wait until the temperature is below 50˚C Wait until the temperature is below 50˚C (122˚F) before removing the coolant system (122˚F) before removing the coolant system pressure cap. pressure cap. Failure to do so can cause personal injury Failure to do so can cause personal injury from heated coolant spray.
  • Page 153 ③ Fill the cooling system with clean water. ※ Be sure to vent the engine and aftercooler Be sure to vent the engine and aftercooler for complete filling. for complete filling. ※ Do not install the surge tank cap or the new Do not install the surge tank cap or the new coolant filter.
  • Page 154 160D7A6MI02 7) 7) CHECK CHARGE AIR COOLER CHECK CHARGE AIR COOLER Inspect the charge air cooler for dirt and debris blocking the fins. Check for cracks, holes, or other damage. If damage is found, please contact Hyundai distributor. 160D7A6MA21 7-25...
  • Page 155 8) 8) FAN BELT FAN BELT Examine if the fan belt is worn out and sunk in the pulley groove, and if it is, replace it. Push the belt halfway between the fan drive pulley and alternator pulley at a specified force 98 N (10 kgf, 22 lbf) to measure the deflection (1).

  • Page 156: Cleaning Of Air Cleaner

    CLEANING OF AIR CLEANER CLEANING OF AIR CLEANER (1) (1) Removal Removal Outer element ① Double element type Double element type Remove the cover by pulling off the clamps, and loosen the wing nut to pull out the outer Clamp element.
  • Page 157 FUEL TANK FUEL TANK Fuel Cap Fill fuel fully when system the operation to minimize water condensation, and check it with Fuel tank fuel gauge before starting the machine. Drain the water and sediment in the fuel tank by opening the drain cock. ※...

  • Page 158: Replacement Of Fuel Filter

    REPLACEMENT OF FUEL FILTER REPLACEMENT OF FUEL FILTER Remove the fuel filter cartridge (1) with filter wrench. Apply a thin layer of fuel to the surface of the new filter cartridge gasket before you put it on. Tighten the new cartridge by hand. Open the fuel valve and bleed the fuel system.
  • Page 159 CHECK OF EGR COOLER CHECK OF EGR COOLER (1) (1) Exhaust gas passage Exhaust gas passage ① Block the EGR cooler exhaust gas outlet (2). ② Attach an air hose to the EGR cooler exhaust gas inlet (1) and then submerge it in a water tank.
  • Page 160 Replacement of oil separator element Replacement of oil separator element Be sure to stop the engine before Be sure to stop the engine before replacement the oil separator element. replacement the oil separator element. ① Remove the cover (2). ② Remove the oil separator element (4) and O-ring (3).

  • Page 161: Hydraulic Oil Check

    The diesel particuate filter shall be 35D9AENG15 cleaned every 3000 hours. cleaned every 3000 hours. 1 Body (DPF outlet) ※ Please contact your Hyundai service Please contact your Hyundai service 2 Filter comp (DPF) center or local dealer. center or local dealer. 3 Collar (DPF)

  • Page 162: Filling Hydraulic Oil

    FILLING HYDRAULIC OIL FILLING HYDRAULIC OIL Stop the engine to the position of level check. Check air breather filter and replace it if Air breather necessary. Loosen cap and fill the oil to the specified level. Start engine after filling and operate the work equipment several times.

  • Page 163: Change The Hydraulic Oil

    CHANGE THE HYDRAULIC OIL CHANGE THE HYDRAULIC OIL Lower the forks on the ground and extend the tilt Air breather 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.
  • Page 164 REPLACEMENT OF ELEMENT IN REPLACEMENT OF ELEMENT IN HYDRAULIC TANK BREATHER HYDRAULIC TANK BREATHER Loosen the cap and relieve the pressure in the Air breather tank. Loosen the screw and remove the cover. Pull out the filter. Replace the filter with new one. Screw Reassemble by reverse order of disassembly.
  • Page 165 TIRE PRESSURE TIRE PRESSURE Inappropriate tire pressure is a primary cause for tire damage. Insufficient tire pressure will damage internal carcass of tire. Repeated excessive bending will damage or break the carcass. Excessive pressure will also cause premature damage of tire. Recommended tire pressure (When tire is cooled) Size...

  • Page 166: Replacement Of Tire

    Do not use recycled wheel parts. Do not use recycled wheel parts. When removing lockering or inflating tire, use When removing lockering or inflating tire, use safety cable or chain to ensure safety. safety cable or chain to ensure safety. B e s u r e t o b l e e d a i r b e f o r e r e m o v i n g B e s u r e t o b l e e d a i r b e f o r e r e m o v i n g lockering.
  • Page 167 ② Loosen slightly all wheel mounting. ·Tools : Socket 32mm Torque wrench Extension bar ③ Lift the machine with a jack. ④ Loosen all wheel mounting nuts and replace the tire. Torque wrench 160D7MI37 (3) (3) Direction of tire to be installed Direction of tire to be installed ①...

  • Page 168: Check Transmission Oil Level

    CHECK TRANSMISSION OIL LEVEL CHECK TRANSMISSION OIL LEVEL The oil level check must be carried out as follows; Oil level check (weekly). At horizontally standing machine. Transmission in neutral position. In cold start phase, the engine must be running about 2~3 minutes at idling speed, and the marking on the oil level gauge must then be lying above the cold start mark COLD.
  • Page 169 Remove the transmission oil filter cartridge. Dispose of the used transmission oil filter cartridge properly. Clean the filter cartridge mounting base. Transmission oil filter Remove any part of the filter cartridge gasket that remains on the filter cartridge mounting base. 50D7AMI43 Apply a light coat of oil to the gasket of a new transmission oil filter cartridge.

  • Page 170: Differential Case

    CLEANING TRANSMISSION AIR BREATHER CLEANING TRANSMISSION AIR BREATHER Air breather Remove dust or debris around the air breather. Remove the air breather and wash it with cleaning oil. 50D7AMI45 DIFFERENTIAL CASE DIFFERENTIAL CASE (1) (1) Differential oil Differential oil Park the truck in a level place. Set the mast Filler plug vertical, and raise the forks approx.
  • Page 171 LUBRICATION LUBRICATION Supply grease through the grease nipple, using grease gun. After lubricating, clean off spilled grease. Press the parking brake switch and fix front Press the parking brake switch and fix front and rear tires with blocks. and rear tires with blocks. Set the mast and forks in a stable position Set the mast and forks in a stable position and turn the hydraulic safety lock valve into...
  • Page 172 MAINTENANCE OF WORK EQUIPMENT MAINTENANCE OF WORK EQUIPMENT Lubricate to each point of working device. Lubricate the grease to grease nipple in accordance with lubrication intervals. Description Fork adjustment cylinder pin Fork shaft Tilt cylinder pin Load chain Mast support pin Chain sheave pin ※...

  • Page 173: Electrical System

    8. ELECTRICAL SYSTEM 8. ELECTRICAL SYSTEM 1) 1) WIRING, GAUGES WIRING, GAUGES C h e c k r e g u l a r l y a n d r e p a i r l o o s e o r malfunctioning gauges when found.

  • Page 174: Air Conditioner And Heater

    9. AIR CONDITIONER AND HEATER 9. AIR CONDITIONER AND HEATER 1) 1) CLEANING AND REPLACING FILTER CLEANING AND REPLACING FILTER ※ Recircular Always stop the engine before servicing. Always stop the engine before servicing. plenum assy Open the door, loosen the wing bolt and remove the recircular plenum assembly.

  • Page 175: Replacement And Check

    10. REPLACEMENT AND CHECK 10. REPLACEMENT AND CHECK 1) 1) WIRING, GAUGES WIRING, GAUGES Check regularly and repair loose or malfunctioning gauges when found. 13036MI29 2) 2) BATTERY BATTERY (1) (1) Clean Clean ① Wash the terminal with hot water if it is conta- minated, and apply grease to the terminals after washing.

  • Page 176: Air Cleaner Element

    Prior to reinstall the cable, inspect in detail and Prior to reinstall the cable, inspect in detail and Connect (-) lead last confirm the condition of the cables and replace confirm the condition of the cables and replace Neg(-) 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...

  • Page 177: Transmission Oil

    Installation Installation When installing the element, check that the cleaner housing and element cover are completely in close contact then tighten the nut. ※ Make sure that bottom cap are securely installed. If it is loosely installed, dust will be drawn in and Make sure that bottom cap are securely installed.
  • Page 178 5) 5) DIFFERENTIAL CASE DIFFERENTIAL CASE (1) (1) Differential oil Differential oil Park the truck in a level place. Set the mast Filler plug vertical, and raise the forks approx. 1m. Put blocks under the fork carriage. Then stop the engine and apply the parking brake.

  • Page 179: Hydraulic Tank

    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 180: Cooling System

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

  • Page 182: Fuses Replacement

    9) 9) FUSES REPLACEMENT FUSES REPLACEMENT Fuse box A Capacity Related electrical component ⑦ ⑥ ⑤ ④ ③ ② ① ① Horn / Cab tilt CONVER- STOP HORN/ OPSS B CLUSTER/ ② Stop lamp RADIO MONITOR LAMP CAB TILT ③ Cluster / Radio TCU B + ④...

  • Page 183: Functional Tests

    LAMP BULBS REPLACEMENT LAMP BULBS REPLACEMENT Lamp Spec (24V) Head lamp Turn signal lamp Clearance lamp Stop lamp Backup lamp License lamp (option) Beacon lamp (option) Strobe type 50D7AOM69 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 184 (4) (4) Service brakes and inching pedal Service brakes and inching pedal With the direction control in NEUTRAL and the engine running, push the sevice brake pedal fully down and hold. The brakes should apply before the pedal reaches the floorplate. If the pedal continues to creep downward, report the failure immediately.
  • Page 185 (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 186 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 187 OIL PERFORMANCE DESIGNATION: To help achieve proper engine performance and durability, use only engine lubricating oils of the proper quality. For diesel engines, HYUNDAI recommends that you use motor oil that meets API service classification API CH-4 or better (SAE 15W-40) for diesel engines.

  • Page 188: Air Cleaning

    (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. 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.
  • Page 189 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 190 All chains must be replaced if any link has wear of 3% or more, or if any of the damaged conditions notes above are found during inspection. Order replacement chains from your HYUNDAI dealer. Replace all chains as a set. Do not remove factory lubrication or paint new chains. Replace anchor pins and worn or broken anchors when installing new chains.

  • Page 191: Handling Truck In Extremely Hot Places

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

  • Page 192: Cold Weather Operation

    12. COLD WEATHER OPERATION 12. 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 193: Recommendation Table For Lubricants

    SAE 10W-30/15W-40 (API CJ-4 class or better) T/M oil Shell DONAX TD Axle oil Mobil fluid 424 Hydraulic oil ISO VG46/VG68, Hyundai genuine long life hydraulic oil ★1 ISO VG15, Conventional hydraulic oil Grease Lithium base grease NLGI No.2 Fuel ASTM D975-No.2...

  • Page 194: Fuel And Lubricants

    14. FUEL AND LUBRICANTS 14. FUEL AND LUBRICANTS Ambient temperature˚C (˚F) Service point Kind of fluid Capacityℓ (U.S. gal) (-58) (-22) (-4) (14) (32) (50) (68) (86) (104) ★ SAE 5W-40 SAE 30 Engine oil 13.2 SAE 10W Engine oil (3.49) SAE 10W-30 SAE 15W-40...

  • Page 195: Specifications

    8. SPECIFICATIONS 8. SPECIFICATIONS 1. SPECIFICATION TABLE 1. SPECIFICATION TABLE 50D7ASP011 Model Unit 50D-7A 60D-7A 70D-7A Capacity kg (lb) 5000 (11000) 6000 (13500) 7000 (15500) ← ← Load center mm (in) 600 (24") Weight(Unloaded) kg (lb) 8883 (19580) 9550 (21050) 10218 (22530) ←...

  • Page 196: Specification For Major Components

    2. SPECIFICATION FOR MAJOR COMPONENTS 2. SPECIFICATION FOR MAJOR COMPONENTS 1) 1) ENGINE ENGINE Item Unit Specification Model Kubota V3800 Type Vertical, water-cooled, 4-cycle DI diesel engine Cooling Method Water cooling Number of cylinders and arrangement 4-cylinders, In-line Firing order 1-3-4-2 Combustion chamber type Direct injection...

  • Page 197: Steering Unit

    STEERING UNIT STEERING UNIT Item Unit Specification Type Load sensing/Non load reaction/Dynamic signal Capacity cc/rev Rated flow 22.7 POWER TRAIN DEVICES POWER TRAIN DEVICES Item Specification Model ZF 3WG94 Torque converter Type 3 Element, 1 stage, 2 phase Stall ratio 2.526 : 1 Type Full auto, power shift...

  • Page 198: Tightening Torque

    3. TIGHTENING TORQUE 3. TIGHTENING TORQUE Item Size kgf·m lbf·ft Engine mounting bolt, nut M10×1.5 6.9±1.3 50±9.4 Engine Engine bracket mounting bolt M12×1.25 12.2±3.0 89±21.7 Radiator mounting bolt, nut M12×1.25 12.3±3.0 89±21.7 Hydraulic pump mounting bolt M16×2.0 29.7±4.5 215±32.3 Hydraulic MCV mounting bolt, nut M12×1.75 12.8±3.0...

  • Page 199: 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 caution lamp fails ·Oil filter element clogged. ·Replace element. to go out. ·Loose or worn oil pipe joint leaks oil. ·Check and repair.

  • Page 200: 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 201: Torque Flow System

    3. TORQUE FLOW SYSTEM 3. TORQUE FLOW SYSTEM Trouble symptom Probable cause Remedy 1. Excessive oil ·Improper oil level. ·Check oil level. Add or drain oil as temperature rise 1) Torque converter necessary. ·Impeller interfering with surroundings. ·After draining oil from oil tank and transmission, check and replace interfering parts.
  • Page 202 Trouble symptom Probable cause Remedy 3.Low output power ·Insufficient hydraulic pressure : 1) Torque converter - Low oil level. - Check oil level and add oil - Air sucked in. - Check joints and pipes. If necessary, retighten joint or repla- ce packing.
  • Page 203 Trouble symptom Probable cause Remedy 4.Unusual oil pressure ·Control valve malfunctioning. 1) Oil pressure is high (1)Check for spool operation. If necessary, replace valve. (2)Check for clogging of small hole in valve body. If necessary, clean or repair. ·Cold weather. (high oil viscosity) ·When atmospheric temp is below fr- eezing point (when normal oil pressure is recover-...
  • Page 204 Trouble symptom Probable cause Remedy ·Foreign matter intruding into oil pass- ·Disassemble, check and repair or 5. Power is not transmitted (Continue) age to clutch. replace. ·Shaft spline worn. ·Disassemble, check and replace. ·Oil leaks from oil seal. ·Disassemble and check for wear of 6.

  • Page 205: 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 206: Brake System

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

  • Page 207: 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 208: Testing And Adjusting

    10. TESTING AND ADJUSTING 10. TESTING AND ADJUSTING 1. ENGINE SYSTEM 1. ENGINE SYSTEM 1) 1) EASE OF STARTING, NOISE EASE OF STARTING, NOISE Set gear shift lever at NEUTRAL. Forward Neutral Reverse 160D7OM45 Pull the parking lever to LOCK position. Turn ON start switch, automatically heat- ing operated.

  • Page 209: Radiator Cap

    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 210 7) 7) FAN BELT FAN BELT Check that fan belt is not damaged. Alt. pulley pulley Check inside of belt also. If bottom of 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 211: Drive System

    2. DRIVE SYSTEM 2. DRIVE SYSTEM 1) 1) GEAR SHIFT LEVER GEAR SHIFT LEVER (1) (1) Neutral starting Neutral starting Engine can be started only when the shifting lever is in neutral position. (2) (2) Shifting FWD/REV lever Shifting FWD/REV lever ①...
  • Page 212 (3) (3) Inching pedal Inching pedal ·Adjust stopper bolt (1) so that pedal angle is "H". ± - Pedal angle (H) : 35。 1。 ·Adjust bolt (2) so that brake pedal interconnects with inching pedal at inching pedal stroke, 22 mm (0.9 in). 50D7ATA05 10-5...

  • Page 213: Travel System

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

  • Page 214: Steering System

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

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