Hyundai 50D-9 User Manual (English)

Questions and Answers:

K
Kelli MoralesAug 25, 2025
How to fix oil pressure warning lamp that won't turn off in Hyundai 50D-9?
- K
  Kathleen WilsonAug 25, 2025
  If the oil pressure warning lamp in your Hyundai Forklifts stays on, it could be due to several reasons. First, check the oil level in the oil pan and add oil if it's low. Another possible cause is a clogged oil filter element, which would require replacement. Also, inspect the oil pipe joints for any looseness or wear that may be causing leaks, and repair as necessary.
A
Alexander SparksAug 25, 2025
Why does the radiator pressure valve spout steam in my Hyundai 50D-9?
- T
  Tracy MelendezAug 26, 2025
  If the radiator pressure valve in your Hyundai Forklifts is spouting steam, it could be due to a lack of cooling water or water leakage, in which case you should add water or repair the leak. Another possible cause is a loose fan belt, so adjust the belt accordingly. Additionally, dust and scale accumulation in the cooling system can cause this issue, so change the water and clean the interior of the cooling system.
V
velasquezedwardAug 26, 2025
What to do if the water temperature gauge on my Hyundai 50D-9 indicates red range on the right?
- S
  Steven RhodesAug 27, 2025
  If the water temperature gauge on your Hyundai Forklifts is in the red range on the right, it could be due to a clogged or damaged radiator fin, which would need to be cleaned or repaired. Another possibility is a faulty thermostat or water temperature gauge, requiring replacement. Also, check if the radiator filler cap is loosening; retighten it or replace the packing.
J
Justin RichAug 27, 2025
Why is my Hyundai 50D-9 engine emitting whitish or bluish smoke?
- R
  Richard MahoneyAug 27, 2025
  If your Hyundai Forklifts engine is emitting whitish or bluish smoke, it could be due to an excessive quantity of oil in the oil pan, in which case you should reduce the oil quantity. Another possible cause is poor quality fuel, so replace it with the specified fuel.
H
Hunter BryanSep 13, 2025
Why does the alternator make abnormal sounds in my Hyundai Forklifts?
- M
  Michelle MartinezSep 14, 2025
  If the alternator in your Hyundai Forklifts is making abnormal sounds, it's likely that the alternator is defective and needs to be replaced.
D
Destiny JacksonSep 12, 2025
What causes abnormal sounds in the valve or valve unit of Hyundai 50D-9?
- J
  jsanchezSep 12, 2025
  If the valve or valve unit in your Hyundai Forklifts is making abnormal sounds, it could be due to several reasons. One possibility is that the oil inlet pipe of the oil pump is sucking air, requiring repair or replacement. Another cause could be a faulty valve with unbalanced oil pressure, or a dented or clogged pipe, in which case you should adjust the valve set pressure and check the specified oil pressure. Insufficient air bleeding can also lead to these sounds, so bleed the air completely.
I
ijonesSep 12, 2025
Why doesn't the heater signal turn red on my Hyundai Forklifts?
- M
  Mathew DyerSep 12, 2025
  If the heater signal on your Hyundai Forklifts doesn't turn red, it could be due to faulty wiring, so check and repair any wiring issues. Another possible cause is a damaged glow plug, which would need to be replaced.
A
Amanda DanielsSep 4, 2025
Why does the charge lamp light during normal engine operation in Hyundai 50D-9 Forklifts?
- E
  Elizabeth MillerSep 4, 2025
  If the charge lamp lights up during normal engine operation in your Hyundai Forklifts, it could be due to a defective charge lamp, which would need to be replaced. Another possible cause is faulty wiring, so check and repair any wiring issues.
S
Samuel CampbellSep 2, 2025
Why does the starting motor stop before the engine starts on my Hyundai Forklifts?
- G
  Gabriel TaylorSep 2, 2025
  If the starting motor in your Hyundai Forklifts stops before the engine starts, this could be due to faulty wiring, so check and repair any wiring issues. Another possible cause is insufficient battery voltage, so try recharging the battery.
K
Kevin HudsonSep 3, 2025
Why does the steering wheel drag on my Hyundai 50D-9 Forklifts?
- C
  Carrie SpencerSep 3, 2025
  If the steering wheel on your Hyundai Forklifts drags, it could be due to several reasons. Low oil pressure is a possibility, so check the locknut and repair as needed. Other potential causes include a faulty bearing, spring spool, reaction plunger, or ball-and-screw assembly, which may require cleaning or replacement. Additionally, check if the sector shaft adjusting screw is excessively tight and adjust it, or if the gears are poorly meshing, which needs correction. A fatigued flow divider coil spring might also be the cause, requiring replacement.

Hyundai 50D-9 Specifications

General

Rated Load	5000 kg
Engine Type	Diesel
Tire Type	Pneumatic
Transmission	Automatic
Fuel Type	Diesel
Load Capacity	5000 kg
Lifting Height	3000 mm
Fork Length	1, 220 mm

Summary

A Message to Hyundai Lift Truck Operators

Introduction to the Manual

Routine Servicing and Maintenance

Regular maintenance is essential for economy, utilization, and safety of the lift truck.

Operator Daily Inspection - Safety and Operating Checks

Daily inspection before driving ensures safe operation. It's an OSHA requirement.

Planned Maintenance Program

Recommended regular inspections and maintenance by trained mechanics for optimal safety.

Service Manual Reference

In-depth service information for trained personnel is found in the Service Manual.

How to Use This Manual

Section 1: Safety Hints

Reviews and illustrates accepted practices for safe operation of a lift truck.

Section 2: Operating Hazards

Warns of conditions that could cause damage to the truck or injury to personnel.

Section 3: Know Your Truck

Describes major components, systems, controls, and features of the truck and their functions.

Section 4: Operator Maintenance and Care

Details on performing operator's daily safety inspection and refueling the lift truck.

Section 5: Starting and Operating Procedures

Specific instructions on safe, efficient operation of your lift truck.

Section 6: Emergency Starting and Towing

Instructions for towing a truck in an emergency and using jumper cables.

Section 7: Planned Maintenance and Lubrication

Describes the Planned Maintenance (PM) program, including inspections and schedules.

Section 8: Specifications

Provides reference information and data on features, components, and maintenance items.

Section 9: Troubleshooting

Provides trouble symptoms, causes, and methods of remedy for common issues.

Section 10: Testing and Adjusting

Gives instructions for testing and adjusting various truck systems for optimal performance.

EC Regulation Approval Details

Safety Labels Overview

Label Location Information

Always keep safety labels clean. Replace if lost or damaged.

Label Description and Purpose

Familiarize with specific warning labels on the truck. Replace damaged or missing labels.

1. Safety Hints

Daily Inspection Procedures

Inspect truck at the beginning of each shift and fill out maintenance/lubrication table.

Do's and Don'ts for Safe Operation

Lists essential safety practices and prohibitions for operating the lift truck.

Seat Belt Usage

Always buckle up the seat belt for safety. Seat belts can reduce injuries.

No Riders Policy

Only the operator should be on the truck. Never transport personnel on the forks.

Pedestrian Safety Awareness

Watch where you are going and for pedestrians. Sound horn at intersections and blind spots.

Operator Protection Measures

Stay inside the cabin. Keep body within confines. Do not operate without cabin/guard.

Fork Safety Guidelines

Never allow anyone to walk under raised forks. Do not use lift trucks for overhead work.

Pinch Point Hazard Avoidance

Keep hands, feet, and legs out of the mast. Do not use the mast as a ladder.

Travel Safety Precautions

Travel with load near floor, mast tilted back. Never lift/lower load when truck is in motion.

Grades, Ramps, Slopes, and Inclines

Never turn on a grade, loaded or unloaded. Follow specific procedures for inclines.

Tip Over Prevention and Response

Explains lateral and longitudinal tip over causes and conditions.

Surface and Capacity Awareness

Avoid conditions causing tip over or traction loss. Know truck and load weight.

Parking Procedures

Never park on a grade. Come to a complete stop. Lower forks and set parking brake.

Refueling Safety Precautions

Check for oil leakage. Keep away from fire. Wipe off spills.

Safe Mounting and Dismounting

Use provided step when getting on/off. Do not jump up or down.

Operator Safety Rules

All functions require operator seated. Buckle seat belt. Lock parking brake before exiting.

Side Shift Operation Safety

Do not put side loads. Restrict sideshift with raised load. Avoid overloading or uneven loading.

2. Operating Hazards

Loose Loads Hazard

Loose or unbalanced loads are dangerous. Center wide loads, stack and band loose material.

Long and Wide Loads Hazard

Long/wide loads need more room. Slow down and watch clearance. Long loads reduce capacity.

Rear Swing Hazard Awareness

When turning, ensure rear end doesn't swing into racks or posts. Watch for pedestrians.

Low Overhead Clearance Hazard

Know truck height. Watch overhead clearance. Moving into structures can tip truck or spill load.

Fast Turns and High Loads Hazard

Slow down before turning. Fast turns with raised loads can tip truck.

Right Angle Stacking Hazard

When stacking or moving raised load, avoid sharp turns and move slowly.

Chain Slack Hazard

Slack chains mean rail/carriage hang-up. Raise forks before moving.

Pallet and Skid Hazards

Do not use damaged pallets. Ensure pallet/skid is in good condition.

Electrical Lines Hazard

Watch electrical lines when moving truck with raised mast. Operating near lines is dangerous.

Lifting Loads Hazard

Never permit persons to stand under lifted load. Never use wire rope to lift.

Fork Positioner Operation Hazard

Do not operate fork positioner with load or fork arm on ground. Operate levers smoothly.

3. Know Your Truck

General Component Locations

Identifies major components of the truck with numbered diagram and list.

Data and Safety Plates

Explains truck data, capacity plates, and decals for identification and safety.

Cab Devices Overview

Describes ergonomically designed console box and suspension seat for operator comfort.

Instrument Cluster Details

Details gauges, lamps, buttons, and LCD display for monitoring truck status.

Warning Lamps Explained

Explains various warning lamps on the dashboard and their meanings.

Pilot Lamps Explained

Explains various pilot lamps on the dashboard and their functions.

Cluster Button Functions

Describes the function of each button on the cluster control panel.

LCD Display Information

Details the main screen and communication error display on the LCD.

Main Menu Navigation

Outlines the main menu structure for Equipment, Maintenance, and Display settings.

Equipment Selection and Settings

Guides through selecting equipment, model, tilt, and rear angle settings.

Weight Sensor Settings

Covers cross-section, load weight adjustment, initialization, and weight display settings.

ESL Setting Configuration

Details setting ON/OFF functions for ignition limitation and time for starting.

Vehicle Speed Limit Adjustment

Guides on setting the maximum speed and AEB settings.

Finger Tip Lever Settings

Explains setting lever position, pull/push values, and neutral values.

Lever Deadzone Adjustment

Describes setting lever deadzone to prevent value output errors of neutral state.

Valve Setting Procedures

Guides on setting current values for each valve coil and maximum movement.

Maintenance Menu Options

Covers current failure history, maintenance management, signal status, and password change.

LCD Display Settings

Explains LCD adjustment, time setting, unit setting, language setting, and phone number.

Unit Settings Configuration

Guides on changing units for temperature, speed, weight, and pressure.

Language Settings

Instructions for setting the language used by the device, supporting multiple languages.

Transmission Message Display Function

Explains display usage with gear selector, indicating speed, direction, and errors.

Display Indicators During Operation

Table detailing symbols, meanings, and remarks for display indicators during operation.

Error Code Definitions

Explains the structure of error codes and lists meanings of first numbers.

List of Error Codes

Lists error codes by number and their corresponding error meanings.

Switches Overview

Illustrates and labels various switches on the control panel.

Start Switch Operation

Describes the three positions (OFF, ON, START) of the start switch.

Hazard Switch Functionality

Explains use for parking or loading, and battery discharge warning.

Inching Switch Operation

Details how pressing the switch applies inching operation to the pedal.

Parking Brake Switch Function

Used for parking brake lock/release. Release before gear selection.

Main Light Switch Operation

Operates head lights and tail lamps in two steps.

Rear Work Lamp Switch (Option)

Used to operate work lamps.

Auto/Manual Changeover Switch

Selects manual or automatic modes for the autoshift function.

Cabin Tilt Switch Operation

Used for tilting the cabin for service. Sound horn before tilting.

Hand Pump Lever for Cabin Tilt

Lever used for tilting the cabin, turning clockwise/counterclockwise.

Fuel Warmer Switch Function

Switch used to heat the fuel of the pre-heater.

Beacon Switch (Option)

Switch to turn on the strobe light.

Inc/Decrement Switch Function

Adjusts engine low rpm by 25 rpm.

Top Wiper and Washer Switch

Operates wiper and washer on top of the cab.

Horn Button Functionality

Pressing the button on the multifunction switch sounds the horn.

Control Levers Overview

Explains operation of lift, tilt, side shift, and fork positioner levers.

Lift Lever Operation

Controls lifting and lowering of forks. Lifting speed by accelerator, lowering by lever only.

Tilt Lever Operation

Controls forward and backward tilting of the mast. Speeds controlled by tilt lever and accelerator.

Side Shift Lever Control

Controls left and right movement of the side shift.

Fork Positioner Lever Control

Controls fork positioner for outreach/pucker and independent LH/RH fork movement.

Gear Selector Lever Function

Selects gear for forward/reverse stages and controls speed.

Steering Wheel Operation

Operates steering function. Moves truck left/right.

Brake Pedal Function

Generates braking force to stop the truck. Do not rest foot on pedal unnecessarily.

Accelerator Pedal Operation

Controls engine speed. Engine runs at low idling unless pressed.

Inching Pedal Function

Used for fine control of forward/reverse movement when handling loads.

Steering Wheel Lever Adjustment

Lever for adjusting steering wheel tilt and telescope.

Engine Hood Opening Procedure

Pull handle to open engine hood.

Air Conditioner Controls

Details operation of A/C button, outlet control, temperature knob, air inlet, and fan speed.

Air Conditioner Button Operation

Pushing button operates A/C system. Determines cooling function.

Outlet Control Button Function

Regulates airflow direction. Pilot lamp turns on when pushed.

Temperature Control Knob

Regulates air temperature, red zone for cool, blue for heat.

Air Inlet Control Button

Regulates inlet air. Pilot lamp ON for fresh air, OFF for recirculation.

Fan Speed Control Knob

Controls fan speed automatically or manually.

Other Cab Components

Details cigar lighter and 12V socket functions and specifications.

Handsfree System (Option)

Allows dialing calls or conversing without handset. Use remote controller for calls.

Wireless Handsfree Pairing

Selects handsfree mode, pairs phone via Bluetooth, and deactivates pairing.

Remote Controller Functions

Controls power, volume, mode selection, call functions, and handsfree operation.

Handsfree Microphone Function

Transfers user voice to receiver when making calls by handsfree.

Seek Button Functionality

Stops radio at next frequency, selects MP3 songs from USB.

Mute Button Operation

Short press mutes or cancels mute.

Mode Button Operation

Selects desired mode (Radio, MP3, AUX).

Monitor System Overview

Explains monitor adjustment, buttons, and OSD menu.

Operation Camera Set

Sets the number of camera channels on screen. Displays single, dual, or quad camera views.

Gear Linkage Mode Settings

Camera channel switches automatically based on gear state (forward/backward).

Brightness Setting Adjustment

Adjusts the display brightness.

Language Setting Configuration

Sets the language used by the device, supporting multiple languages.

4. Operator Maintenance and Care

Daily Safety Inspection Procedures

Operator must inspect truck condition and safety before operation.

Functional Checks

Checks operation of truck controls, gauges, and safety equipment before starting.

Inspection Conclusion

Do not operate if maintenance problem exists. Use "Out of service" tag.

New Truck Operation Suggestions

Recommendations for initial 100 hours operation to enhance performance.

Fuel Safety Practices

Stop engine when refueling. Keep away from fire. Wipe off spills.

5. Starting and Operating Procedures

Before Operating the Truck

Read manual, be trained/authorized. Operate only from designated position. Inspect truck before use.

Pre-Operation Checks

Perform a thorough walk-around check before starting the engine for safety and longevity.

Pre-Start Engine Checks

Check for water/oil leaks, and check tire air pressure and rims.

Coolant Level Check

Check coolant level in reservoir tank. Add mixture of antifreeze/water if insufficient.

Engine Oil Level Check

Stop engine, pull dipstick, check oil level. Add oil if low.

Fan Belt Tension Check

Check belt tension and inspect for damage. Replace belt if unacceptable.

Cooling Fan Inspection

Inspect fan blades for cracks, loose rivets, or bent parts. Check mounting.

Battery Checks and Maintenance

Battery maintenance needs care and safety. Refer to replacement section.

Hydraulic Oil Level Check

Rest fork, stop engine, check oil level from gauge. Add oil if necessary.

Prefilter Check and Maintenance

Check WIF lamp, drain water from prefilter bowl, or replace element.

Multi Function Switch Operation

Controls front wiper/washer and turning signals. Check washer fluid level.

Pedal Checks and Adjustments

Check inching and brake pedals for catching or abnormal heaviness.

Seat Adjustment Procedures

Adjust seat for contours, reduce fatigue, and enhance work efficiency.

Buckling Up Safety

Always wear seat belt. Failure to wear results in injury or death.

Starting from a Safe Condition

Ensure seated, seat belt buckled, parking brake applied, forks lowered, controls understood.

General Starting and Operating Tips

Inspect truck before use. Turn off lights/equipment during cranking. Avoid excessive cranking.

Starting and Stopping Engine Procedures

Check indicator lights, start engine at normal temp, cold weather, and inspect after start.

Stopping the Engine Safely

Stop engine properly to avoid damage. Run at mid-range speed if overheated.

Traveling on Slopes Safety

Never travel down slope in neutral. Never turn on slope. Be careful on slopes to prevent tip over.

Operating Safely Guidelines

Watch path, protect self and others, no riders, maintain full control, drive smoothly.

Load Handling Procedures

Handle loads within capacity, stable loads only. Do not lift items that may fall.

Adjusting Load Forks

Space forks apart as load allows. Adjust carriage height. Slide hanger bar.

Load Placement on Forks

Do not elevate load with one fork. Do not elevate load with ends of forks. Load should be 2/3 of fork length.

Traveling with Load Safety

Travel low, tilted back. Observe traffic, watch clearances. Be aware of tail swing.

Picking Up and Moving Loads

Approach load slowly, align truck. Ensure load is centered and forks are under.

Stacking Loads Safely

Approach stack slowly, align truck. Raise load, move forward, tilt mast, lower carefully.

Shut Down Procedure

Park safely, stop truck, neutral position, set brake, lower forks. Turn off engine, remove key.

Storage Procedures

Prepare truck for storage: wash, cover, protect parts, manage battery. Operate monthly.

Transport Precautions

Contact dealer for advice. Check travel route clearance. Secure ramps. Back truck slowly.

Loading and Unloading by Crane

Check truck specs for hoisting. Use correct wire rope, rubber plate. Place crane properly.

6. Emergency Starting and Towing

How to Tow a Disabled Truck

Follow procedures to tow safely. Do not tow if brakes/steering are faulty or on inclines.

Parking Brake Release for Towing

Loosen bolt to minimum 3mm to release parking brake for towing.

Using Battery Jumper Cables Safely

Explains safe procedure for jump-starting a dead battery using another truck.

7. Planned Maintenance and Lubrication

Introduction to Planned Maintenance

Only trained personnel should perform maintenance. Neglecting maintenance is hazardous.

Safe Maintenance Practices

Follow industry and government safety standards for maintenance. Wear safety glasses and hard hat.

Instructions Before Maintenance

Inspect and service based on service meter. Shorten intervals for dusty areas. Practice related details.

General Maintenance Precautions

Start maintenance after full knowledge. Drain oil/coolant properly. Relieve hydraulic pressure.

Hydraulic Hose and Pipe Installation Precautions

Be careful with hose/pipe joints. Avoid contamination. Use genuine parts.

Periodical Replacement of Safety Parts

Lists parts with recommended replacement intervals, not judged by visual inspection.

Major Components Location for Maintenance

Diagram showing locations for maintenance checks and service points.

Maintenance Check List by Interval

Detailed table of check items, services, intervals, and remarks for regular maintenance.

Planned Maintenance Procedures

Visual inspection of truck, cabin, and load handling components.

Fork Inspection and Maintenance

Inspect load forks for cracks, bends, wear, and height difference. Replace if worn or damaged.

Wheel and Tire Maintenance

Check wheels, tires for condition, wear, lug nuts, and pressure.

Tilting Cabin Procedures

Perform cabin tilting safely. Locate truck on stable floor, apply brake, remove cover.

Engine Oil and Filter Service

Check oil level, check for discoloration/deterioration. Change oil/filter. Use correct oil type.

Coolant Level Check

Check coolant level in reservoir tank. Add mixture of antifreeze and water.

Radiator Flushing and Refilling

Change coolant. Drain system, flush with solution, then refill with clean water.

Radiator and Oil Cooler Cleaning

Clean radiator fins with compressed air. Inspect for damage. Clean charge air cooler.

Fan Belt Tensioner Maintenance

Check tensioner arm/pulley for cracks. Verify belt contact. Check drive belt location on pulley.

Air Cleaner Cleaning Procedures

Clean primary element with compressed air. Inspect for damage. Safety element should not be cleaned.

Fuel Tank Maintenance

Fill fuel fully. Drain water/sediment. Remove and clean strainer if contaminated.

Prefilter Maintenance

Inspect/drain water bowl daily. Replace element every 500 hours. Lubricate new bowl seal.

Fuel Filter Replacement

Remove filter cartridge, apply gasket lubricant, tighten, open valve, bleed system, check for leaks.

Fuel System Bleeding

Loosen plug, hand-prime pump until air bubbles are gone, tighten plug. High pressure fuel warning.

DEF Dosing Unit Filter Service

Remove DEF filter cap, equalizing element, and dosing unit filter element. Clean cap and threads.

DEF/AdBlue Tank Level Check

Check DEF/AdBlue® tank level daily. Do not tamper with system or use non-spec fluid.

Fuel Leakage Precautions

Be careful with fuel hose, pump, filter connections as leakage can cause fire.

Hydraulic Oil Level Check

Lower forks, stop engine, check oil level gauge on left side of tank. Add oil if necessary.

Hydraulic Oil Filling Procedure

Stop engine, check breather, fill oil to specified level, operate equipment, check level again.

Hydraulic Oil Change Procedure

Lower forks, relieve pressure, drain oil, replace filter, fill with recommended oil, start engine.

Return Filter Cleaning and Replacement

Remove flange, filter, replace element, install cover. Check torque.

Hydraulic Tank Breather Element Replacement

Loosen cap, relieve pressure, remove screw/cover, pull element, replace, reassemble. Check torque.

Pilot Line Filter Replacement

Loosen case, pull element, clean case, replace element/O-ring, reassemble.

Brake Line Filter Cleaning

Remove strainer, wash with cleaning oil, install and tighten with specified torque.

RCV Lever Lubrication

Remove bellows and grease joint and sliding parts.

Tire Pressure Management

Check tire pressure. Inspect for cracks, wear, and embedded objects. Inflate to recommended pressure.

Tire Replacement Procedure

Tire replacement requires skills. Contact tire shop. Identify tires needing replacement.

Tire Separation Process

Lower fork, pull parking brake, loosen wheel mounting, jack up truck, remove nuts, take off tire.

Tire Mounting Procedure

Lightly tighten nuts, lower jack, tighten to specified torque.

Storing Tires After Removal

Store tires in warehouse or erect fence outdoors. Stand on level ground and block securely.

Transmission Oil Level Check

Check oil level at idling speed when warm. Ensure level is in HOT zone.

Transmission Oil and Filter Change

Warm transmission oil, stop engine, relieve pressure, drain oil, replace filter, fill, start engine.

Differential Case Oil Check

Park truck level, set mast vertical, raise forks, block carriage, stop engine, apply brake. Check oil.

Lubrication Points

Supply grease through nipples. Clean fittings. Lubricate mast/tilt cylinder bushings. Lubricate lift chains.

Fork Replacement Procedure

Lower fork carriage, release retainer, remove cover, slide hanger bar, remove fork.

Work Equipment Maintenance

Lubricate work equipment points. Check for wear and damage. Mount dust seal correctly.

Work Equipment Support

Fit stand under raised forks securely. Set control levers to hold position.

8. Electrical System

Wiring and Gauges Check

Check wiring and gauges regularly. Repair loose or malfunctioning gauges.

Welding Repair Safety

Follow procedures before welding. Shut off engine, disconnect battery, connect ground lead.

9. Air Conditioner and Heater

Filter Cleaning and Replacement

Stop engine, remove plenum assembly, clean with compressed air. Inspect filter after cleaning.

Air Conditioner Usage Precautions

Open window periodically. Avoid overcooling cab. Change air occasionally.

Seasonal Check

Ask service center for refrigerant replenishment or maintenance.

Off-Season Check

Operate A/C 2-3 times monthly to avoid oil film loss in compressor.

10. Replacement and Check

Battery Maintenance Procedures

Wash terminals, apply grease. Beware of explosive gas. Wear protective glasses. Recycle batteries.

Transmission Oil Check

Check oil level at idling speed when warm. Ensure level is in HOT zone.

Cooling System Maintenance

Clean radiator fins with compressed air. Check drain valves, add water/cleaner, run engine, drain.

Tire Replacement Procedure

Replace tires carefully. Follow procedures for loosening nuts, jacking, and mounting.

Fuse Replacement Procedure

Turn switch OFF, open fuse box, replace fuse with same capacity. Check fuse-electrical component relationship.

Lamp Bulb Replacement

Replace lamp bulbs after checking fuses and wiring harness.

Functional Tests

Test engine start, horn, hour meter, indicator lights, brakes, and inching pedal.

Parking Brake Test

Check parking brake holding capability on a grade. Do not operate if brakes are faulty.

Lift Mechanism and Controls Test

Test tilt and lift levers for smooth movement, check for binding, adequate clearance.

Auxiliary Controls Test (Option)

If equipped with attachment, test control lever and briefly operate attachment.

Steering System Test

Inspect steering system for looseness, damage, leaks. Check for smooth operation. Never operate with steering fault.

Direction, Braking, and Inching Tests

Check travel area, brake pedal, reverse operation, inching pedal. Report any problems.

Engine Air Cleaner Maintenance

Check air cleaner for damage/contamination. Ensure hose connection. Service element based on hours or indicator.

Battery Maintenance Procedures

Inspect battery for damage, leaks. Clean terminals. Beware of explosive gases.

Engine Oil and Filter Check

Check oil level, add if low. Change oil/filter based on hours or application. Use correct oil type.

Hydraulic Sump Tank Check

Check fluid level at operating temp. Park on level surface, lower forks. Add fluid if low. Check fluid condition.

Transmission Fluid Check

Check transmission fluid level at operating temperature. Fill to HOT zone. Change fluid based on hours or condition.

Lubrication of Truck Chassis Components

Inspect chassis components, lubricate grease points. Clean fittings. Lubricate mast/tilt cylinder bushings. Lubricate lift chains.

Air Cleaning Procedures

Maintain clean condition. Avoid dirt, dust, lint. Wipe spills. Use air hose with adapter for cleaning.

Lift Chain Wear and Replacement Criteria

Defines criteria for chain wear and replacement based on length, span, and pitch.

11. Handling Truck in Extremely Hot Places

Cooling System Maintenance in Hot Conditions

Wash cooling system with anticorrosion liquid. Use clean, soft water for circulation.

12. Cold Weather Operation

Low Temperature Preparation

Replace lubrication oil, use low pour point fuel, use antifreeze mixture for cooling system.

Battery Care in Cold Weather

Maintain battery charge over 75%. Insulate against cold. Add distilled water if electrolyte is low.

13. Lubricant Recommendations

New Truck Lubricant Specifications

Lists recommended fuel, coolant, and lubricant specifications for new trucks.

8. Specifications

Specification Table

Provides detailed specifications for various models including capacity, dimensions, and performance.

Major Component Specifications: Engine

Lists specifications for the engine, including model, type, cooling, dimensions, and performance data.

Major Component Specifications: Main Pump

Lists specifications for the main pump, including type, displacement, operating pressure, and rated speed.

Major Component Specifications: Main Control Valve

Lists specifications for the main control valve, including type, operating method, and pressure.

Major Component Specifications: Steering Unit

Lists specifications for the steering unit, including type, capacity, rated flow, and relief pressure.

Major Component Specifications: Power Train

Lists specifications for the power train, including torque converter, transmission, axle, wheels, brakes, and steering.

Tightening Torque Specifications

Provides a table of specified tightening torques for various bolts and nuts on the truck.

9. Troubleshooting

Engine System Troubleshooting

Lists common engine system trouble symptoms, probable causes, and remedies.

Electrical System Troubleshooting

Lists common electrical system trouble symptoms, probable causes, and remedies.

Torque Flow System Troubleshooting

Lists common torque flow system symptoms, probable causes, and remedies for converter and transmission.

Low Output Power Issues

Lists symptoms, probable causes, and remedies for low output power in torque converter and transmission.

Abnormal Oil Pressure

Lists symptoms, probable causes, and remedies for high or low oil pressure and transmission issues.

Power Transmission and Oil Leakage Issues

Lists probable causes and remedies for power transmission issues and oil leakage.

Steering System Troubleshooting

Lists common steering system trouble symptoms, probable causes, and remedies.

Brake System Troubleshooting

Lists common brake system trouble symptoms, probable causes, and remedies.

Hydraulic System Troubleshooting

Lists common hydraulic system trouble symptoms, probable causes, and remedies.

Mast Troubleshooting

Lists problems, causes, and remedies related to mast operation and noise.

Fork Troubleshooting

Lists problems, causes, and remedies related to fork abrasion, distortion, and fatigue.

10. Testing and Adjusting

Engine System Testing

Procedures for testing engine starting ease, noise, idling, and accelerator pedal response.

Radiator Cap Check

Inspect pressure regulator spring, negative pressure valve. Replace cap if packing is damaged. Handle hot cap carefully.

Fuel Filter Maintenance

Replace fuel filter periodically. Always use genuine parts. Check for leaks after replacement.

Engine Oil Check

Check oil level, check for discoloration/deterioration. Refer to specifications for quantity.

Engine Oil Filter Service

Replace oil filter cartridge. Use filter wrench to remove assembly.

Fan Belt Tension Check

Check belt tension and inspect for damage. Replace belt if unacceptable.

Fan Inspection

Move fan by hand to check for looseness. Tighten mounting bolt.

Drive System: Gear Shift Lever

Engine starts only in neutral. Push lever forward for forward clutch, backward for reverse clutch.

Drive System: Oil Leakage Check

Check for oil leakage from torque converter, transmission, or control valve. Replace packing if oozing.

Pedal Adjustment Procedures

Adjust accelerator and brake pedal angles according to specifications.

Inching Pedal Adjustment

Adjust stopper bolt for pedal angle and brake pedal interconnect with inching pedal stroke.

Travel System: Tire Checks

Check tire pressure, visually inspect for cracks/wear. Measure tread depth. Check for uneven wear.

Hub Nuts Check

Use wrench to check for loose hub nuts. Tighten to specified torque.

Rim Side Ring Inspection

Check rim side ring for deformation or cracks. Check rear rim connecting nut torque.

Steering Axle Clearance Check

Check axle clearance and measure clearance between center pin and bushing.

Drive Axle Inspection

Check drive axle for deformation, cracks, or weld damage. Check mounting bolt torque.

Steering Wheel Play Test

Set wheels forward, turn wheel left/right, measure movement range. Test play with engine idling.

Knuckle Inspection

Visually inspect knuckle or use crack detection. Check tire wear if knuckle is bent.

Steering Axle Camber Check

Measure camber. Ask assistant to drive at minimum turning radius. Adjust turning angle stopper bolt.

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Hyundai 50D-9 User Manual

Table of Contents

Questions and Answers:

Hyundai 50D-9 Specifications

Summary

A Message to Hyundai Lift Truck Operators

Introduction to the Manual

Routine Servicing and Maintenance

Operator Daily Inspection - Safety and Operating Checks

Planned Maintenance Program

Service Manual Reference

How to Use This Manual

Section 1: Safety Hints

Section 2: Operating Hazards

Section 3: Know Your Truck

Section 4: Operator Maintenance and Care

Section 5: Starting and Operating Procedures

Section 6: Emergency Starting and Towing

Section 7: Planned Maintenance and Lubrication

Section 8: Specifications

Section 9: Troubleshooting

Section 10: Testing and Adjusting

EC Regulation Approval Details

Safety Labels Overview

Label Location Information

Label Description and Purpose

1. Safety Hints

Daily Inspection Procedures

Do's and Don'ts for Safe Operation

Seat Belt Usage

No Riders Policy

Pedestrian Safety Awareness

Operator Protection Measures

Fork Safety Guidelines

Pinch Point Hazard Avoidance

Travel Safety Precautions

Grades, Ramps, Slopes, and Inclines

Tip Over Prevention and Response

Surface and Capacity Awareness

Parking Procedures

Refueling Safety Precautions

Safe Mounting and Dismounting

Operator Safety Rules

Side Shift Operation Safety

2. Operating Hazards

Loose Loads Hazard

Long and Wide Loads Hazard

Rear Swing Hazard Awareness

Low Overhead Clearance Hazard

Fast Turns and High Loads Hazard

Right Angle Stacking Hazard

Chain Slack Hazard

Pallet and Skid Hazards

Electrical Lines Hazard

Lifting Loads Hazard

Fork Positioner Operation Hazard

3. Know Your Truck

General Component Locations

Data and Safety Plates

Cab Devices Overview

Instrument Cluster Details

Warning Lamps Explained

Pilot Lamps Explained

Cluster Button Functions

LCD Display Information

Main Menu Navigation

Equipment Selection and Settings

Weight Sensor Settings

ESL Setting Configuration

Vehicle Speed Limit Adjustment

Finger Tip Lever Settings

Lever Deadzone Adjustment

Valve Setting Procedures

Maintenance Menu Options

LCD Display Settings

Unit Settings Configuration

Language Settings

Transmission Message Display Function

Display Indicators During Operation

Error Code Definitions