Hyundai HDF 50-7S Manuals

Manuals and User Guides for Hyundai HDF 50-7S. We have 2 Hyundai HDF 50-7S manuals available for free PDF download: Service Manual, Manual

Hyundai HDF 50-7S Service Manual (518 pages)

Brand: Hyundai | Category: Forklifts | Size: 37 MB

Table of Contents

11
- Section 1 General
  15
- Group 1 Safety Hints
  16
- Group 2 Specifications
  20
- Group 3 Periodic Replacement
  28
- Section 2 Removal and Installation of Unit
  29
- Group 1 Structure
  30
- Group 2 Removal and Installation of Unit
  31
- Section 3 Power Train System
  49
- Group 1 Structure and Operation
  49
- Group 2 Operation and Maintenance
  76
- Group 3 Disassembly and Assembly
  103
- Group 4 Adjustment
  175
- Section 4 Brake System
  180
- Group 1 Structure and Function
  181
- Group 2 Operational Checks and Troubleshooting
  197
- Group 3 Tests and Adjustments
  202
- Section 5 Steering System
  205
- Group 1 Structure and Function
  206
- Group 2 Operational Checks and Troubleshooting
  216
- Group 3 Disassembly and Assembly
  218
- Section 6 Hydraulic System
  247
- Group 1 Structure and Function
  248
- Group 2 Operational Checks and Troubleshooting
  262
- Group 3 Disassembly and Assembly
  266
- Section 7 Electrical System
  279
- Group 1 Component Location
  280
- Group 2 Electrical Circuit
  281
- Group 3 Component Specification
  292
- Group 4 Connector Destination
  293
- Group 5 Troubleshooting
  295
General

331
- External View
  332
- Fuel System - Flow Diagram
  334
- Lubrication System - Flow Diagram
  334
- System Flow Diagrams
  334
- Cooling System - Flow Diagram
  335
- Inlet and Exhaust System - Flow Diagram
  335
- Engine Serial Number Location
  336
- Main Specifications
  337
- Disassembling
  340
- Reassembling
  340
- Tips on Disassembling and Reassembling
  340
Service Data

341
- General
  342
- Maintenance Service Data
  342
- Basic Engine
  343
- Fuel System
  346
- Lubrication System
  346
- Cooling System
  347
- Inlet and Exhaust System
  347
- Electrical System
  348
- Basic Engine
  349
- Fuel System
  349
- Major Bolt Tightening Torque
  349
- Tightening Torque Table
  349
- Cooling System
  350
- Electrical System
  350
- Inlet and Exhaust Systems
  350
- Lubrication System
  350
- Metric Automobile Screw Thread
  351
- Metric Course Screw Thread
  351
- Standard Bolt and Nut Tightening Torque
  351
- Standard Stud Tightening Torque
  351
- Regarding Submission of Parts for EPA Exhaust Gas Regulation
  352
Disassembly of Basic Engine

361
- Disassembling and Inspecting Cylinder Head and Valve Mechanism
  362
- Disassembling Rocker Shaft Assembly
  363
- Removing Cylinder Head Bolt
  363
- Removing Rocker Shaft Assembly
  363
- Removing Cylinder Head Assembly
  364
- Removing Valve and Valve Spring
  364
- Removing Valve Stem Seal
  364
- Disassembling and Inspecting Flywheel
  365
- Removing Flywheel
  366
- Removing Rear Plate
  366
- Disassembling and Inspecting Damper, Gear Case, Timing Gear and Camshaft
  367
- Removing Cover
  369
- Removing Crankshaft Pulley and Damper
  369
- Measuring Timing Gear Backlash
  370
- Removing Timing Gear Case
  370
- Measuring Idler Gear and Camshaft Gear End Play
  371
- Removing Fuel Injection Pump
  371
- Removing Oil Pan
  371
- Removing Oil Strainer
  371
- Removing Camshaft
  372
- Removing Idler Gear
  372
- Removing Oil Pump Gear
  372
- Removing PTO Drive Gear
  372
- Installing Camshaft Gear and Thrust Plate
  373
- Removing Front Plate
  373
- Removing Oil Pump
  373
- Separating Camshaft Gear
  373
- Disassembling and Inspecting Piston, Connecting Rod, Crankshaft and Crankcase
  374
- Pulling out Piston
  375
- Removing Carbon Deposits from the Upper Part of Cylinder Liner
  375
- Removing Connecting Rod Cap
  375
- Removing Main Bearing Cap
  376
- Removing Piston Pin and Piston
  376
- Removing Piston Ring
  376
- Removing Crankshaft
  377
- Removing Tappet
  377
Inspection and Repair of Basic Engine

379
Reassembly of Basic Engine

409
- Installing Crankshaft
  410
- Installing Main Bearing
  410
- Installing Tappet
  410
- Installing Thrust Plate
  410
- Reassembling Piston, Connecting Rod, Crankshaft and Crankcase
  410
- Inserting Side Seal
  411
- Installing Main Bearing Cap Bolt
  411
- Installing Main Bearing Caps
  411
- Measuring Crankshaft End Play
  412
- Reassembling Piston and Connecting Rod
  412
- Installing Piston Ring
  413
- Preparation for Installing Pistons
  413
- Installing Connecting Rod Bolt and Connecting Rod Bearing
  414
- Installing Pistons
  414
- Installing Connecting Rod Cap
  415
- Installing Front Plate
  416
- Installing Oil Pump
  416
- Reassembling Timing Gear and Camshaft
  416
- Installing Camshaft
  417
- Installing Camshaft Gear and Thrust Plate
  417
- Installing PTO Drive Gear
  417
- Installing Idler Gear
  418
- Inspecting and Adjusting Timing Gear after Installation
  419
- Inspecting Backlash and End Play
  419
- Installing Fuel Injection Pump
  419
- Installing Oil Pump Gear
  419
- Installing Front Oil Seal
  420
- Installing Oil Strainer
  420
- Installing Timing Gear Case
  420
- Installing Oil Pan
  421
- Installing Cover
  422
- Installing Crankshaft Pulley and Damper
  422
- Installing Flywheel
  423
- Installing Oil Seal
  423
- Installing Rear Plate
  423
- Reassembling Flywheel
  423
- Cleaning Cylinder Head Bottom Surface
  424
- Installing Valve and Valve Spring
  424
- Installing Valve Stem Seal
  424
- Reassembling Cylinder Head and Valve Mechanism
  424
- Installing Cylinder Head Assembly
  425
- Installing Cylinder Head Gasket
  425
- Tightening Cylinder Head Bolts
  425
- Inserting Push Rod
  426
- Installing Rocker Shaft Assembly
  426
- Reassembling Rocker Shaft Assembly
  426
- Adjusting Valve Clearance
  427
- Determining Top Dead Center of No. 1 Cylinder Compression Stroke
  427
- Installing Rocker Cover
  427
- When Replacing the Damper with a New One
  427
- When Reusing the Damper
  427
Fuel System

429
Lubrication System

443
Cooling System

457
- Removing Cooling System
  458
- Removing Thermostat
  458
- Removing Water Pump, Water Pump Pulley and V-Belt
  459
- Disassembling and Inspecting Thermostat
  460
- Disassembling, Inspecting and Reassembling Cooling System
  460
- Inspecting Thermostat
  461
- Disassembling Water Pump
  462
- Inspecting Water Pump
  462
- Installing Cooling System
  463
- Installing Water Pump, Water Pump Pulley and V-Belt
  463
- Installing Thermostat
  464
Inlet and Exhaust Systems

465
- Removing Turbocharger
  466
- Removing Turbocharger, Inlet and Exhaust Systems
  466
- Removing Inlet Manifold
  467
- Removing Exhaust Manifold
  468
- Disassembling, Inspecting and Reassembling Inlet and Exhaust Systems
  469
- Measuring Exhaust Manifold Distortion
  469
- Disassembling and Inspecting Turbocharger
  470
- Installing O-Ring
  471
- Removing Compressor Cover
  471
- Removing Turbine Housing
  471
- Installing Compressor Cover
  472
- Installing Snap Ring
  472
- Cleaning
  473
- Measuring Axial Clearance of Cartridge Assembly
  473
- Reassembling Turbocharger
  474
- Installing Exhaust Manifold
  476
- Installing Turbocharger, Inlet and Exhaust Systems
  476
- Installing Inlet Manifold
  477
- Installing Turbocharger
  478
Electrical System

479
- Removing Electrical System
  480
- Removing Starter
  480
- Handling Precaution
  481
- Inspecting Alternator Operation
  481
- Inspection before Removing Alternator
  481
- Removing Alternator
  482
- Removing Glow Plug
  484
- Disassembling, Inspecting and Reassembling Electrical System
  485
- Inspecting Magnetic Switch
  485
- Inspection before Disassembling Starter
  485
- No Load Test
  486
- Disassembling and Inspecting Starter
  487
- Removing Pinion Set
  488
- Removing Armature and Yoke
  489
- Removing Brush Holder and Brush Assembly
  489
- Removing Magnetic Switch
  489
- Removing Overrunning Clutch
  489
- Removing Rear Bracket
  489
- Inspecting and Repairing Starter
  490
- Inspecting Brush Holder for Insulation
  490
- Inspecting Brushes for Wear
  490
- Measuring Brush Spring Load
  490
- Measuring Commutator Radial Runout
  490
- Checking Armature Coil
  491
- Measuring Commutator Outside Diameter12-13
  491
- Measuring Undercut Depth
  491
- Inspecting Field Coil
  492
- Inspecting Front Bracket
  492
- Inspecting Gears of Starter
  492
- Inspecting Overrunning Clutch Operation
  492
- Inspecting Rear Bracket
  492
- Inspecting Magnetic Switch
  493
- Inspecting Starter Relay
  493
- Installing Gear Shaft
  494
- Reassembling Starter
  494
- Disassembling and Inspecting Alternator12-17
  495
- Separating Front Bracket from Stator
  495
- Removing Field Coil
  496
- Removing Pulley
  496
- Removing Rear Bearing
  496
- Removing Front Bearing
  497
- Removing Rectifier Assembly
  497
- Removing Regulator Assembly
  497
- Removing Stator
  497
- Inspecting and Repairing Alternator
  498
- Inspecting Rectifier
  498
- Inspecting Stator
  498
- Measuring Field Coil
  499
- Installing Rectifier Assembly and Regulator Assembly
  500
- Reassembling Alternator
  500
- Installing Front Bearing
  501
- Installing Pulley
  501
- Installing Rear Bearing
  501
- Installing Stator
  501
- Assembling Stator and Front Bracket
  502
- Continuity Test of Glow Plug
  502
- Heating Test of Glow Plug
  502
- Inspecting Glow Plug
  502
- Continuity Test of Magnetic Valve
  503
- Inspecting Magnetic Valve (Stop Solenoid)
  503
- Inspecting Magnetic Valve (Stop Solenoid) Operation
  503
- Installing Magnetic Valve (Stop Solenoid)12-25
  503
- Installing Electrical System
  504
- Installing Glow Plug
  504
- Installing Alternator
  505
- Installing Starter
  507
Adjustment and Operation

509
- Adjusting Engine
  510
- Adjusting Valve Clearance
  510
- Inspecting and Adjusting Valve Clearance13-2
  510
- Inspecting Valve Clearance
  510
- Bleeding Fuel Filter
  511
- Bleeding Fuel System
  511
- Draining Fuel Filter
  511
- Draining Fuel System
  511
- Adjusting Fuel Injection Timing
  512
- Inspecting and Adjusting Fuel Injection Timing
  512
- Adjusting V-Belt Tension
  515
- Inspecting V-Belt
  515
- Inspecting V-Belt and Adjusting V-Belt Tension
  515
- Break-In Operation
  516
- Break-In Operation Time
  516
- Inspecting Engine Condition after Starting up
  516
- Inspection and Adjustment after Break-In Operation
  516
- Starting up
  516
- Continuous Load Test
  517
- Engine Equipment Condition
  517
- Engine Output Adjustment
  517
- Low Idle Test
  517
- Operation Load Test
  517
- Other Inspections
  517
- Performance Test (JIS Standard)
  517
- Standard Atmospheric Conditions
  517
- Test Items and Purposes
  517
- Calculation of Corrected Power
  518

Hyundai HDF 50-7S Manual (177 pages)

Brand: Hyundai | Category: Forklifts | Size: 9 MB

Table of Contents
1
Machine Serial Number
8
Safety Hints
9
Daily Inspection
9
Do's and Don'ts
10
Seat Belts
12
No Riders
13
Pedestrians
14
Operator Protection
15
Fork Safety
16
Pinch Points
17
Travel
18
Grades, Ramps, Slopes and Inclines
19
Tip over
20
Surface and Capacity
22
Parking
23
Refueling
24
Step
25
Operator's Safety Rules
26
Operating Hazards
27
Loose Loads
27
Long and Wide Loads
28
Rear Swing
28
Low Overhead Clearance
29
Fast Turns and Hiqh Loads
29
Drop-Offs
30
Right Angle Stacking
30
Chain Slack
31
Pallets and Skids
31
Caution for Electrical Lines
32
Lifting Loads
33
Know Your Truck
34
General Locations
34
Data/Safety Plates and Decals
37
For Usa Only
37
Instruments and Controls
40
Indicator Symbols
43
Engine Oil Pressure Warning Lamp
44
Battery Charge Warning Lamp
45
Operating Lever and Switch
53
Start Switch
53
Head Lamp Switch
53
Turn Signal Switch
55
Horn Button
56
Operator Maintenance and Care
59
Daily Safety Inspection
59
Visual Checks
59
Functional Checks
60
Fuel Safety Practices
61
Starting and Operating Procedures
62
Before Operating the Truck
62
Check before Starting
63
Check before Starting Engine
64
Check Brake Fluid
65
Check Coolant Level
65
Check Hydraulic Oil Level
66
Check Parking Brake
67
Seat Adjustment
69
Starting from a Safe Condition
70
General Starting and Operating Tips
71
Starting the Engine
72
Check after Starting Engine
73
Levers and Pedals
75
Operating Safely
77
Load Handling
79
Shut down Procedure
84
Emergency Starting and Towing
85
How to Tow a Disabled Truck
85
How to Use Battery Jumper Cables
87
Planned Maintenance and Lubrication
89
Introduction
89
Safe Maintenance Practices
90
Instructions before Maintenance
93
Proper Maintenance
94
Planned Maintenance Intervals
96
Every 50 Hours Service
99
Every 250 Hours Service
100
Every 500 Hours Service
100
Every 1000 Hours Service
100
When Required
101
Maintenance Locations
102
Maintenance Chart
103
How to Perform Planned Maintenance
106
Wheel and Tires
107
Replacement and Check
108
Removing and Installing
108
Air Cleaner Element
109
Transmission Oil
111
Differential Case
111
Hydraulic Tank
112
Cooling System
113
Tire Replacement
113
Fuses Replacement
114
Functional Tests
116
Air Cleaning
121
Lubrication Chart
124
Greasing Point
127
Handling Machine in Extremely Hot Places
129
Cold Weather Operation
130
Storage
131
Before Storage
131
During Storage
131
After Storage
131
Transport
132
Loading and Unloading by Crane
133
Rear View
133
Recommendation Table for Lubricants
134
New Machine
134
Fuel and Lubricants
135
Specifications
138
Specification Table
138
Main Control Valve
144
Tightening Torque
156
Troubleshooting
158
Engine System
158
Electrical System
159
Steering System
164
Brake System
165
Hydraulic System
167
Testing and Adjusting
168
Engine System
168
Radiator Cap
170
Fuel Filter(Diesel)
170
Engine Oil
170
Drive System
172
Gear Shift Lever
172
Oil Leakage
172
Check Oil Level
174
Travel System
175
Steering Axle
175
Steering System
176
Steering Wheel
176
Adjustment of Parking Brake Lever
177

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Hyundai HDF 50-7S Manuals

Hyundai HDF 50-7S Service Manual (518 pages)

Table of Contents

Table of Contents

General

Service Data

Disassembly of Basic Engine

Inspection and Repair of Basic Engine

Reassembly of Basic Engine

Fuel System

Lubrication System

Cooling System

Inlet and Exhaust Systems

Electrical System

Adjustment and Operation

Hyundai HDF 50-7S Manual (177 pages)

Table of Contents

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Hyundai Categories