Hyundai 15P-7 User manual

CONTENTS
1. GENERAL SAFETY RULES
1. Daily inspection --------------------------------------------------------------------------------------------------------
1-1
2. Do’s and don’ts
--------------------------------------------------------------------------------------------------------
1-2
3. Seat belts
----------------------------------------------------------------------------------------------------------------- 1-3
4. No riders ------------------------------------------------------------------------------------------------------------------- 1-4
5. Pedestrians -------------------------------------------------------------------------------------------------------------- 1-5
6. Operator protection -------------------------------------------------------------------------------------------------- 1-6
7. Loading and unloading by crane ------------------------------------------------------------------------------ 1-7
2. KNOW YOUR TRACTOR
1. General locations ----------------------------------------------------------------------------------------------------- 2-1
2. Safety plates and decals ------------------------------------------------------------------------------------------ 2-2
3. Instruments and controls ------------------------------------------------------------------------------------------ 2-3
4. Instruments panel ---------------------------------------------------------------------------------------------------- 2-4
5. Indicator symbols ----------------------------------------------------------------------------------------------------- 2-5
6. Operating switches and levers --------------------------------------------------------------------------------- 2-7
7. Seat adjustment ------------------------------------------------------------------------------------------------------- 2-10
8. Battery compartment access ----------------------------------------------------------------------------------- 2-10
3. OPERATING PROCEDURES
1. Checks prior to operation ----------------------------------------------------------------------------------------- 3-1
4. BATTERY AND CHARGER
1. Battery charging ------------------------------------------------------------------------------------------------------- 4-1
2. Battery handling ------------------------------------------------------------------------------------------------------- 4-3
3. Battery removal from tractor ------------------------------------------------------------------------------------ 4-5
4. Electric tractor battery maintenance ------------------------------------------------------------------------ 4-7
5. Battery cleaning and care ---------------------------------------------------------------------------------------- 4-8
5. MAINTENANCE AND INSPECTION
1. Body ------------------------------------------------------------------------------------------------------------------------- 5-1
2. Electric system --------------------------------------------------------------------------------------------------------- 5-2
3. Major component location ---------------------------------------------------------------------------------------- 5-2

4. Daily maintenance checks ----------------------------------------------------------------------------------------- 5-4
5. Periodic maintenance checks ------------------------------------------------------------------------------------ 5-5
6. Lubrication ------------------------------------------------------------------------------------------------------------------ 5-6
7. New machine oils ------------------------------------------------------------------------------------------------------- 5-7
8. Recommended lubricants ------------------------------------------------------------------------------------------ 5-7
6. SPECIFICATIONS
1. Specifications ------------------------------------------------------------------------------------------------------------ 6-1

Battery tracktors are specialized machines with unique operating characteristics, designed to perform a
specific job. Their function and operation is not like a car or ordinary truck. They required specific
instructions and rules for safe operation and maintenance.
Safe operation of battery tractors is of primary importance to HYUNDAI.
Our experience with battery tractor accidents has shown that when accidents happen and people are
killed or injured, the causes are:
ÂÂ Operator not properly trained
 Operator not experienced with battery tractor operation
ÂÂ Basic safety rules not followed
 Battery tractor not maintained in safe operating condition
For these reasons, HYUNDAI wants you to know about the safe operation and correct maintenance of
your battery tractor.
This manual is designed to help you operate your battery tractor safely.
This manual shows and tells you about safety inspections and the important general safety rules and
hazards of battery tractor operation. It describes the special components and features of the battery
tractor and explains their function. The correct operating procedures are shown and explained.
Illustrations and important safety messages are included for clear understanding. A section on
maintenance and lubrication is included for the battery tractor mechanic.
The operator's manual is not a training manual. It is a guide to help trained and authorized operators
safely operate their battery tractor by emphasizing and illustrating the correct procedures. However, it
cannot cover every possible situation that may result in an accident. You must watch for hazards in your
work areas and avoid or correct them. It is important that you know and understand the information in
this manual and that you know and follow your company safety rules!
Be sure that your equipment is maintained in a safe condition. Do not operate a damaged or
malfunctioning battery tractor. Practice safe operation every time you use your battery tractor. Let's join
together to set high standards in safety.
Remember, before you start operating this battery tractor, be sure you understand all driving
procedures. It is your responsibility, and it is important to you and your family, to operate your battery
tractor safely and efficiently.
Be aware that the Federal Occupational Safety and Health Act(OSHA) and state laws require
that operators be completely trained in the safe operation of battery tractors; It is also an
(OSHA) requirement that a machine inspection be performed before every shift. If you need
training in operating or inspecting your battery tractor, ask your supervisor.
HYUNDAI battery tractors 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 battery tractor unless you have been trained in safe battery tractor repair
procedures and are authorized by your employer.
This manual describes procedures for operation, handling, lubrication, maintenance, checking and
adjustment. It will help the operator realize peak performance through effective, economical and safe
machine operation.
A MESSAGE TO HYUNDAI BATTERY TRACTOR OPERATORS

HYUNDAI welcomes you to the growing group of professionals who own, operate and maintain
HYUNDAI battery tractors. We take pride in the long tradition of quality products and superior value the
HYUNDAI name represents. This manual familiarizes you with safety, operating, and maintenance
information about your new battery tractor. It has been specially prepared to help you use and maintain
your HYUNDAI battery tractor in a safe and correct manner.
Your HYUNDAI battery tractor 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. Some trucks are also
furnished with equipment to help you operate safely; for example, parking brake and horn are standard
equipment.
Safe, productive operation of a battery tractor requires both skill and knowledge on the part of the
operator. The operator must know, understand, and practice the safety rules and safe driving and load
handling techniques described in this manual. To develop the skill required, the operator must become
familiar with the construction and features of the battery tractor and how they function, the operator must
understand its capabilities and limitations, and see that it is kept in a safe condition.
Routine Servicing and Maintenance
Regular maintenance and care of your battery tractor is not only important for economy and utilization
reasons; it is essential for your safety. A faulty battery tractor is a potential source of danger to the
operator, and to other personnel working near it. As with all quality equipment, keep your battery tractor
in good operating condition by following the recommended schedule of maintenance.
Operator Daily Inspection - Safety and Operating Checks
A battery tractor should always be examined by the operator, before driving, to be sure it is safe to
operate. The importance of this procedure is emphasized in this manual with a brief illustrated review
and later with more detailed instructions. HYUNDAI dealers can supply copies of a helpful Drivers
Daily Checklist. It is an OSHA requirement.
Planned Maintenance
In addition to the daily operator inspection, HYUNDAI recommends that a planned maintenance and
safety inspection program(PM) be performed by a trained and authorized mechanic on a regular basis.
The PM will provide an opportunity to make a thorough inspection of the safety and operating condition
of your battery tractor. Necessary adjustments and repairs can be done during the PM, which will
increase the lift or components and reduce unscheduled downtime and increase safety. The PM can be
scheduled to meet your particular application and battery tractor usage.
The procedures for a periodic planned maintenance program that covers inspections, operational
checks, cleaning, lubrication, and minor adjustments are outlined in this manual. Your HYUNDAI dealer
is prepared to help you with a Planned Maintenance Program by trained service personnel who know
your battery tractor and can keep it operating safely and efficiently.
Service Manual
In-depth service information for trained service personnel is found in Service Manual.
INTRODUCTION

This manual is a digest of essential information about the safe operation, the features and functions and
explains how to maintain your battery tractor. This manual is organized into six major parts:
Section 1. General Safety Rules, reviews and illustrates accepted practices for safe operation of a
battery tractor.
Section 2. Know your tractor, describes operating components, systems, controls, and other features
of your truck and tells how they function.
Section 3. Operating procedures, discusses specific instructions on the safe, efficient operation of your
battery tractor.
Section 4. Battery and charger, presents details on how to perform the charging and maintaining
battery system.
Section 5. Maintenance and inspection, discusses specific instructions on maintenance and how to
check out the battery tractor.
Section 6. Specifications, provides reference information and data on features, components, and
tightening torque.
ö The descriptions and specifications included in this manual were in effect at the time of printing.
HYUNDAI reserves the right to make improvents 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.
The examples, illustrations, and explanations in this manual should help you improve your skill and
knowledge as a professional battery tractor operator and take full advantage of the capabilities and
safety features of your new battery tractor.
The first section of the manual is devoted to a review, with illustrations and brief messages, of general
safety rules and the major operating hazards you can encounter while operating a battery tractor. Next,
you will find descriptions of the components of your specific battery tractor model and how the
instruments, gauges, and controls operate. Then, you will find a discussion of safe and efficient
operating procedures, followed by instructions on how to tow a disabled battery tractor. The later
sections of the manual are devoted to maintenance and battery tractor specifications.
Take time to carefully read the K
Know Your Tractor section. By acquiring a good basic understanding of
your battery tractor's features, and how they function, you are better prepared to operate it both
efficiently and safely.
In Planned Maintenance, you will find essential information for correct servicing and periodic
maintenance of your tractor, including charts with recommended maintenance intervals and component
capacities. Carefully follow these instructions and procedures.
Each major section has its own table of contents, so that you can find the various topics more easily.
HOW TO USE THIS MANUAL

We urge you to first carefully read the manual from cover to cover. Take time to read and understand
the information on general safety rules and operating hazards. 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
battery tractor's features, operation, or manuals.
Operate your battery tractor safely; careful driving is your responsibility.
Drive defensively and think about the safety of people who are working nearby. Know your tractor's
capabilities and limitations. Follow all instructions in this manual, including all symbols (
messages to avoid damage to your battery tractor or the possibility of any harm to yourself or others.
This manual is intended to be a permanently attached part of your battery tractor. Keep it on the tractor
as a ready reference for anyone who may drive or service it. If the battery tractor you operate is not
equipped with a manual, ask your supervisor to obtain one and have it attached to the tractor. And,
remember, your HYUNDAI dealer is pleased to answer any questions about the operation and
maintenance of your battery tractor and will provide you with additional information should you require it.
ö
)

GUIDE
1. DIRECTION
The direction of this machine indicate forward,
backward, right and left when machine is in the
travelling direction.
Inform following when you order parts or the machine is out of order.
Front
Left Right
Rear
MACHINE SERIAL NUMBER
It's shown of the front-left side of the frame.
1)
BP157OM01
2. SERIAL NUMBER
BP157OM02
Important safety hint.
It indicates matters which can cause the great loss on the machine or the surroundings.
It indicates the useful information for operator.
3. SYMBOLS
ö

1-1
At the beginning of each shift, inspect your
battery tractor and fill out a check, maintenance
and lubrication table.
Check for damage and maintenance problems.
Have repairs made before you operate the
battery tractor.
Do not make repairs yourself. Battery tractor
mechanics are trained professionals. They
know how to make repairs safe.
1. GENERAL SAFETY RULES
1. DAILY INSPECTION
BP157OM00

1-2
Do watch for pedestrians.
2. DO'S AND DON'TS
D35AOM03
Do wear safety equipment when required.
D35AOM05
Don't mix drugs or alcohol with your job.
Don't block safety or emergency equipment.
D35AOM04
D35AOM02
Don't smoke in NO SMOKING areas or when charging.
D35AOM06

1-2-1
Don't operate the truck outdoors in rainy day.
D35AOM031
Don't perform battery charging service in the room without
adequate ventilation.
D35AOM032

1-3
3. SEAT BELTS
Seat belts can reduce injuries.
B207OM10
Always buckle up for the machine
equipped with safety belt.
B207OM09

1-4
BP157OM11
4. NO RIDERS
The operator is the only one who should be
on a battery tractor.
1)

1-5
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.
BP157OM13
Watch for people in your work area even if
your battery tractor has warning lights or
alarms. People may not watch for you.
BP157OM14
Make people stand back, even when you
are parked.
BP157OM15
5. PEDESTRIANS
1)
2)
3)

1-6
Seat belt
6. OPERATOR PROTECTION
BP157OM16
Always keep your body within the confines
of the tractor.
Always buckle up for the machine
equipped with safety belt.
1)

1-7
Check the weight, length, width and height of the
truck referring to the chapter 8, specifications
when you are going to hoist the tractor.
Before loading the tractor, battery must be
removed. Refer to page 4-4 for a safe battery
removal.
7. LOADING AND UNLOADING BY CRANE
Wire rope
Stay
Rubber plate
Wire rope
Stay
BP157OM162
B15AOM136
(X)
(X)
(X)
BP157OM163
1)
Use long wire rope and stay to keep the distance
with the tractor as it should avoid touching with the
truck body.
Put a rubber plate where the wire rope contact
with the tractor's body to prevent damage.
Place crane on the proper place.
Install the wire rope and stay like the illustration.
Make sure wire rope is proper size.
The wrong hoisting method or installation of
wire rope can cause damage to driver and
tractor.
Do not load abruptly.
Keep area clear of personnel.
2)
3)
4)
5)
Do not install the wire to unsafe position such
as seat, steering wheel, front cover, etc.. It can
cause a serious damage to driver and tractor.
If there is any problem to lift a tractor, please
contact your dealer.
Perform the lifting service with skilled service
man.

2-1
2. KNOW YOUR TRACTOR
1. GENERAL LOCATIONS
ÂÂLAYOUT
21
3
4
8
9
14
11
12
13
+
-
01
HYUNDAI
1/10h
56 7
10
BP157GEN01
1 Seat
2 Steering wheel
3 Rear view mirror
4 Parking brake lever
5 Monitor panel
6 Emergency switch
7 Start switch
8 Head lamp
9 Front wheel
10 Rear wheel
11 Battery
12 Hook
13 Battery cover
14 Flasher lamp

2-2
2. SAFETY PLATES AND DECALS
SAFETY PLATE
BP157OM56
BR147OM60
1)

2-3
3. INSTRUMENTS AND CONTROLS
+
-
01
HYUNDAI
1/10h
12 34 5
7
8
9
6
BP157OM62
1 Monitor panel
2 Emergency switch
3 Start switch
4 Parking brake lever
5 Flasher, head lamp switch
6 Direction control lever
7 Accelerator pedal
8 Brake pedal
9 Steering wheel
ö Famaliarize yourself with the controls and follow safe operating procedures.

2-4
4. INSTRUMENT PANEL
2
1
+
-
01
HYUNDAI
1/10h
34567
BP157OM63
1 Hour meter
2 Battery discharge indicator
3 Parking brake indicator
4 Sequence fault warning lamp
5 Drive motor brush warning lamp
6 Seat switch indicator
7 Diagnostic/service warning lamp

2-5
HOUR METER 1)
This indicates the length of total machine operation.
All service intervals for periodic maintenance are based on
service meter readings.
The last digit advances by "1" every six minutes where the
starting switch is at the ON position.
(1)
öö
1/10h
BP157OM66
BATTERY DISCHARGE INDICATOR 2)
The state of battery discharge is indicated by 10 segments on
the display. When fully charged, all 10 segments will be lit and
when fully discharged, all 10 segments will be extinguished,
with each 10% drop in capacity extinguishing 1 segment from
the right.
When the battery charge drops below an warning level(20%),
warning lit segments will flash to warn the driver of this.
(1)
(2)
+
-
01
Red zone
BP157OM67
PARKING BRAKE INDICATOR 3)
This symbol appears if parking brake works.
If appeared, you can drive neither forward nor reverse.
This prevents abnormal operations, such as rapid battery
consumption, overheat of driving motor and wear of brake.
(1)
B15AOM69
5. INDICATOR SYMBOLS
SEQUENCE FAULT WARNING LAMP 4)
This symbol appears if you don't follow the operating sequence
of controller.
To reset this fault, please put direction control lever at
neutral position.
(1)
öö
B15AOM71