Hyundai 50L-7A User Manual

0-1
FOREWORD
1. STRUCTURE
This service manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to
full effect at every opportunity.
This service manual mainly contains the necessary technical information for operations performed in
a service workshop.
For ease of understanding, the manual is divided into the following sections.
SECTION 1 GENERAL
This section gives the general information of the machine and explains the safety hints for
maintenance.
SECTION 2 REMOVAL & INSTALLATION OF UNIT
This section explains the procedures and techniques of removal and installation of each component.
SECTION 3 POWER TRAIN SYSTEM
This section explains the structure of the transmission as well as control valve and drive axle.
SECTION
4 BRAKE SYSTEM
This section explains the brake piping, each component and operation.
SECTION 5 STEERING SYSTEM
This section explains the structure of the steering unit, priority valve, trail axle as well as steering
circuit and operation.
SECTION 6 HYDRAULIC SYSTEM
This section explains the structure of the gear pump, main control valve as well as work equipment
circuit, each component and operation.
SECTION 7 ELECTRICAL SYSTE
M
This section explains the electrical circuit and each component.
It serves not only to give an understanding electrical system, but also serves as reference material for
troubleshooting.
SECTION 8 MAST
This section explains the structure of mast, carriage, backrest and forks.
The specifications contained in this service manual are subject to change at any time and without any
advance notice. Contact your HYUNDAI distributor for the latest information.

Hyundai 50L-7A Specifications

General

Model	50L-7A
Category	Forklifts
Load Capacity	5000 kg
Power Source	Diesel
Tire Type	Pneumatic
Transmission	Automatic
Fuel Tank Capacity	90 l
Lifting Height	3, 000 mm

Summary

Structure Overview

Removal and Installation Procedures

Explains removal and installation procedures for each component.

Power Train System Description

Details the structure of the power train system.

Brake System Description

Explains the brake system, components, and operation.

Steering System Description

Details the steering system, components, and operation.

Hydraulic System Description

Explains the hydraulic system, components, and operation.

Electrical System Description

Explains electrical circuits and components.

Mast Component Structure

Explains the structure of the mast, carriage, backrest, and forks.

General Information Section

Safety Hints for Operation

Details safety precautions for performing work.

Major Component Specifications

Lists specifications for major components.

Technical Specifications

Lists technical specifications for various models and parts.

Component Specifications

Provides specifications for the engine, main pump, and control valve.

Power Train Device Specifications

Major Component Tightening Torque

Torque Chart for Fasteners

Coarse Thread Bolt and Nut Torque

Provides torque chart for coarse thread bolts and nuts.

Fine Thread Bolt and Nut Torque

Provides torque chart for fine thread bolts and nuts.

Recommended Lubricants

Periodic Parts Replacement Schedule

Unit Removal and Installation

Forklift Structure Overview

Illustrates the structure of the forklift with numbered components.

Mast Removal Procedures

Details the removal steps for mast components.

Mast Installation Procedures

Details lift cylinder installation and synchronization adjustment.

Power Train Assembly Procedures

Transmission Assembly

Details the installation of the transmission assembly.

Engine Removal and Installation

Steering Axle Procedures

Power Train System Overview

Power Train Component Structure

Provides an overview of power train components.

Power Train System Operation

Explains how the power train system operates.

Transmission System Specifications

Torque Converter Details

Torque Converter Structure

Details the structure of the torque converter.

Torque Converter Operation

Explains the operation of the torque converter.

Transmission System Details

Transmission Structure

Details the structure of the transmission.

Transmission Operation

Explains the operation of the transmission.

Transmission Input Port Specifications

Transmission Input Port Data

Input Port Specifications

Lists specifications for transmission input port.

Differential Carrier Assembly

Differential Carrier Structure

Details the structure of the differential carrier assembly.

Differential Operation

Explains the operation of the differential.

Drive Axle System

Drive Axle Structure

Details the structure of the drive axle.

Drive Axle Operation

Explains the operation of the drive axle.

Drive Axle Tightening Torque

Disk Brake System

Transmission Inspection and Troubleshooting

Visual Inspection Steps

Drive Check Procedure

Transmission Troubleshooting Guide

Operation Check List

Lists common operational problems and their causes/remedies.

Drive Axle Troubleshooting

Drive Axle Disassembly and Assembly

Wheel Hub Sub-Assembly Disassembly

Differential Carrier Assembly Disassembly

Bevel Pinion Shaft Adjustment

Pinion Shaft Adjustment Procedure

Differential Assembly Procedure

Carrier Assembly and Parking Brake Adjustment

Carrier Assembly Steps

Parking Brake Adjustment

Wheel Hub Assembly

Transmission Disassembly Steps

Transmission Assembly Procedure

Shim Thickness Calculation

Brake System Overview

Disk Brake Specifications

Parking Brake Specifications

Brake Pedal and Piping Structure

Brake Pedal and Piping Structure

Inching Pedal and Linkage Details

Wet Disk Brake System

Wet Disk Brake Structure

Brake Valve Components

Brake Valve Structure

Brake Valve Disassembly

Brake Valve Inspection and Assembly

Brake System Operational Checks

Brake System Troubleshooting

Brake System Tests and Adjustments

Brake System Air Bleeding

Details the procedure for bleeding the brake system.

Brake Pedal Adjustments

Steering System Overview

Steering Hydraulic Circuit

Hydraulic Circuit: Neutral Operation

Hydraulic Circuit: Left Turn Operation

Hydraulic Circuit: Right Turn Operation

Steering Unit Components

Steering Unit Operation

Steering Axle Structure

Steering Axle Structure Diagram

Steering Greasing and Specifications

Steering System Operational Checks

Steering System Operational Checks

Steering System Troubleshooting

Lists common problems, causes, and remedies for the steering system.

Steering Unit Disassembly and Assembly

Steering Unit Structure

Steering Unit Assembly Torque and Tools

Torque Wrench and Tightening Torque

Steering Unit Disassembly Steps

Steering Unit Assembly Steps

Steering Cylinder Components

Steering Cylinder Structure

Steering Cylinder Maintenance Procedures

Steering Cylinder Disassembly

Steering Cylinder Inspection

Steering Cylinder Assembly

Steering Axle Checks and Inspection

Steering Axle Disassembly

Steering Axle Assembly

Hydraulic System Overview

Hydraulic Circuit Diagram

Lift Control Lever Operation

Lift Position Operation

Lower Position Operation

Tilt Control Lever Operation

Forward Tilt Position Operation

Backward Tilt Position Operation

Hydraulic Gear Pump Details

Hydraulic Gear Pump Structure

Main Control Valve Structure

Main Control Valve Structure (2 Spool)

Lift Section Valve Operation

Lift Position Valve Operation

Lower Position Valve Operation

Tilt Section Valve Operation

Tilt Forward Position Valve Operation

Tilt Backward Position Valve Operation

Main Relief Valve Function

Main Relief Valve Pressure Setting

Details the procedure for setting the pressure of the main relief valve.

Main Relief Valve Functionality

Hydraulic Cylinder Components

Lift Cylinder Structure

Tilt Cylinder Structure

Hydraulic System Operational Checks

Fork and Mast Operational Checks

Hydraulic Oil Level Check

Control Valve Pressure Check

Hydraulic System Troubleshooting

Hydraulic System Troubleshooting Guide

Lists problems, causes, and remedies for the hydraulic system.

Hydraulic Gear Pump Troubleshooting

Main Relief Valve Troubleshooting

Lift Cylinder Troubleshooting Guide

Main Pump Disassembly and Assembly

Main Pump Structure

Pump Disassembly Instructions

Pump Assembly Instructions

Main Control Valve Assembly

Main Control Valve Assembly Steps

Electrical System Overview

Electrical Circuit Diagram

Electrical Component Specifications

Electrical System Troubleshooting

Provides troubleshooting steps for electrical issues.

Power Circuit Description

Power Circuit Check Points

Power Circuit Diagram

Starting Circuit Description

Starting Circuit Check Points

Starting Circuit Diagram

Mast System Overview

2-Stage Mast (V Mast) Structure

2-Stage Mast (VF Mast) Structure

3-Stage Mast (TF Mast) Structure

Carriage, Backrest, and Fork Assembly

Mast Operational Checks

Fork Inspection Procedures

Mast Component Operational Checks

Mast Troubleshooting Guide

Mast Problems Troubleshooting

Lists problems, causes, and remedies for mast issues.

Fork Troubleshooting Guide

Mast Roller Adjustments

Inner/Outer Mast Roller Clearance Adjustment

Details adjusting clearance between inner/outer mast rollers.

TF Mast Roller Clearance Adjustments

Inner and Middle Mast Roller Clearance

Details adjusting clearance between inner/middle mast rollers.

Outer and Middle Mast Upper Roller Clearance

Details adjusting clearance for upper rollers between outer and middle mast.

Carriage and Mast Roller Adjustments

Carriage Load Roller Adjustment

Mast Back Up Liner Adjustment

Mast Component Removal and Installation

Forks Removal and Installation

Backrest Removal and Installation

Carriage Assembly Procedure

Side Roller Maintenance

Carriage Load Roller Maintenance

Mast Load Roller and Back Up Liner Procedures

2-Stage Mast (V Mast) Roller/Liner Procedures

2-Stage Mast (VF Mast) Roller/Liner Procedures

3-Stage Mast (TF Mast) Roller/Liner Procedures

Elevating Mast Procedures

V and VF Mast Inner Mast Procedures

TF Mast Inner and Middle Mast Procedures

Mast Chain Procedures

V/VF Mast Chain Sheave Procedures

TF Mast Rear Chain Procedures

Chain Adjustments and Maintenance

Chain Adjustment Importance