Hyundai 15P-7, Manual

Page 1: ...nd 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 MAINTENA...

Page 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 ...

Page 3: ... 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 Pra...

Page 4: ...r 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...

Page 5: ...r 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 haza...

Page 6: ... 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 dr...

Page 7: ... 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 ...

Page 8: ...ance 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 ...

Page 9: ... 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 ...

Page 10: ...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 ...

Page 11: ...1 3 3 SEAT BELTS Seat belts can reduce injuries B207OM10 Always buckle up for the machine equipped with safety belt B207OM09 ...

Page 12: ...1 4 BP157OM11 4 NO RIDERS The operator is the only one who should be on a battery tractor 1 ...

Page 13: ...me 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 ...

Page 14: ...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 ...

Page 15: ...ng 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 t...

Page 16: ...4 8 9 14 11 12 13 0 1 HYUNDAI 1 10h 5 6 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 ...

Page 17: ...2 2 2 SAFETY PLATES AND DECALS SAFETY PLATE BP157OM56 BR147OM60 1 ...

Page 18: ... 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 öFamaliarize yourself with the controls and follow safe operating procedures ...

Page 19: ... 0 1 HYUNDAI 1 10h 3 4 5 6 7 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 ...

Page 20: ...ished 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 0 1 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 cons...

Page 21: ...R 6 This symbol appears if seat switch opens If appeared you can drive neither forward nor reverse For a safe operation please power up the machine with your body on the seat 1 B15AOM70 DIAGNOSTIC SERVICE WARNING LAMP 7 This symbol appears if any failure in controller is detected or error in diagnostic procedure is detected If this warning lamp blinks please notify HYUNDAI dealer of the cycle of g...

Page 22: ...ned off For the backward direction place the lever on the BACKWARD position The electrical brake will be applied by shifting the lever to the opposite position of running direction DIRECTIONAL CONTROL LEVER 2 Forward Backward Neutral BP157OM30 1 2 3 4 When making a left or right turn use this switch to flash the flash lamp to indicate which direction the vehicle is turning to For a right turn plac...

Page 23: ...vehicle will run to the opposite direction after stopping once A ACCELERATOR PEDAL 6 BP157OM80 1 2 When this pedal is depressed the vehicle is braked while the braking lamps attached on the rear light Special care should be required for the operation of the brake at loading BRAKE PEDAL 7 BP157OM81 1 The steering wheel of the vehicle is provided with the knob to allow steering with one hand Perform...

Page 24: ...eft ON for a long time the battery may be discharged EMERGENCY SWITCH 10 ON OFF L255OM17 1 ö This switch is closed automatically when an operator sits down on the seat Before starting the tractor seat switch must be closed otherwise the tractor cannot be started B207OM84 1 ...

Page 25: ... that the seat locking mechanism is engaged The seat mounting base provides an 3 inch fore and aft adjustment of its slide 7 SEAT ADJUSTMENT B207OM85 Battery cover Seat Latch BP157OM18 1 2 8 BATTERY COMPARTMENT ACCESS Pull the latch to release the cover You may tiIt the steering column pylon forward before raising the cover The cover is held closed by weight of seat located on the battery cover 1 ...

Page 26: ...allowance and the parking brake for braking efficiency Check of steering system Check that the steering wheel has no play 2 3 4 Hydrometer BP157OM111 F E T is connected Place the direction control lever to the Forward position and release the parking brake lever thereby the starting preparations are complete Step on the accelerator pedal slowly to start the battery tractor The travelling speed can...

Page 27: ...ccelerator pedal will cause the brake to apply suddenly When applying the electric brake while 2 Forward Backward Neutral BP157OM31 Η Θ Ι Κ P PRECAUTIONS ON OPERATION Check of battery capacity If the level meter indicates the red zone during heavy load operations such as starting full load travelling hill climbing even the battery needs not to be recharged however it incicates that the battery has...

Page 28: ...letion Full charge lamp Lighting on when charging is completed Input disconnect lamp Lighting on when the input supply line is disconnected At this time check the input power Over voltage lamp Lighting on when the manual stop button is pushed or charger voltage is above 66 At this time unplug and disconnect the battery and charger connectors Over current lamp Lighting on when the current is overlo...

Page 29: ...e the performance among the cells that is given equalizing charge Equalizing charge should be given in the following cases A battery that is subject to daily repetition of charge and discharge For the battery equalizing charge should be performed once a month When discharged over the designated capacity When recharge had been delayed after discharge When a short circuit has occurred Equalizing cha...

Page 30: ...irectly upward vertical and no side load or force pressure is exerted on the battery case Be sure the lift hooks are the correct size to fit the lifting eyes of the battery 1 2 3 4 B15AOM129 B15AOM130 If the battery does not have a cover of its own or has exposed terminals and connectors cover the top with a non conductive insulating material e g a sheet of plywood or heavy cardboard prior to atta...

Page 31: ...the following procedure Disconnect the battery connector 1 BP157OM17 Battery cover Seat Latch Open the battery cover BP157OM18 Battery stand BP157OM19 2 Put the battery checking stand to the battery stopper side 3 Battery stand Stopper pin Battery BP157OM20 Disengage the stopper pin Adjust the height of the roller of the stand to that of the roller of the vehicle 4 5 ...

Page 32: ...57OM22 2 10 10 20 30 40 50 St 1 300 1 250 1 200 1 150 S20 1 300 1 250 1 200 1 150 t C Check specific gravity and electrolyte level once a week Specific gravity at a temperature of 20Á C is as follows At charged completion of charge 1 280 At discharged Charging required 1 17 BP157OM23 3 Red color float support Red color ring Float Normal level Check electrolyte level and if it is insufficient refil...

Page 33: ...han 50 percent acid above 1 400 specifics gravity an eye wash fountain must be provided A conveyor overhead hoist or equivalent material handling equipment must be provided for handling batteries E Electric tractor batteries are heavy and awkward to handle They are filled with a very hazardous chemical solution On charge they give off hydrogen and oxygen which in certain concentrations are explosi...

Page 34: ... inflammable gas B15AOM138 2 REFILLING DISTILLED WATER Refill distilled water to maintain the electrolyte level to the specified height before starting equalizing charge because electrolyte is lost through decomposition during charge and also through natural evaporation It is unnecessary to refill dilute sulfuric acid into the battery except the case of losing electrolyte by running over 3 B15AOM1...

Page 35: ...em just in the reverse of disassembling STEERING SYSTEM Since the steering system is particularly an essential part be sure to check each part of the system for alignment damage deformation etc so that it can be always kept under the optimum condition BRAKE Check the brake pedal for play and pedalling allowance when it is stepped on and looseness of each part etc If the tractor slides laterally wh...

Page 36: ...rating point The microswitch is adjusted so that it is closed with turning on the main circuit segment and opened before the segment is turned off Check each terminal for looseness ACCELERATOR Check the microswitch for operating point The microswitch is adjusted so that it is closed to open the slit when the accelerator pedal is stepped on approx 10 when the tractor starts The electric bulb used t...

Page 37: ...box 6 Buzzer 7 Rear wheel 8 Battery 9 Hydraulic oil tank 10 Accelerator 11 Brake system 12 Flasher lamp 13 Monitor panel 14 Hydraulic motor 15 DC DC converter 16 Power steering pump 17 Steering hyd motor 18 Brake pedal 19 Drive motor 20 Harness 21 Controller 22 Contactor 23 Drive unit 1 2 3 4 5 7 8 F1 B M B F2 9 6 10 11 12 13 14 15 16 17 19 18 20 21 22 23 BP157OM113 ...

Page 38: ...eering wheel Check gauges and instruments Check warning lights and hourmeter Check directional and speed controls operation Check for accelerator operation Check optional safety equipment Alarms Lights etc Check for head lamp and work lamp operation Check for flasher lamp operation Check for fuse box Check battery connector s cleanliness Check battery electrolyte level Check hydraulic sump fluid a...

Page 39: ...teering pump Check steering pump motor Check drive motor Check brake pedal condition and wear Check drive unit fluid level Check harness status Check controller DC converter Check contactors Replace contactor tips if roughness is remarkable Replace hydraulic sump fluid and strainer Replace hydraulic sump filter Replace hydraulic sump breather Lubricate steering gear and steering bearing of drive u...

Page 40: ... clean the lubrication port so that the oil should not be contaminated Sine the oil viscosity will be decreased under high temperature resulting in decreased lubrication efficiency be sure to use the oil of high viscosity in summer for normal temperature of over 32Á C and that of low viscosity in winter for normal temperature of under 0Á C 1 2 GO Drive unit gear case Replacement every 6 months BP1...

Page 41: ... for Standardization 8 8 RECOMMENDED LUBRICANTS Service point Kind of fluid Ambient temperature Á C Á F SAE 80W 90LSD API GL 5 ISO VG 46 ISO VG 68 Hydraulic oil tank 10 14 0 32 10 50 20 68 30 86 ISO VG 32 Hydraulic oil Axle Gear oil 1 6 0 4 7 6 2 0 20 4 Capacity U S gal 40 104 15P 7 40T 7 Gear oil GO Hydraulic oil SAE 80W 90LSD API GL 5 ISO VG 46 Specification Description ...

Page 42: ...t Unloaded Drive motor Travel speed Loaded Unloaded Tire FR RR Battery Charger Control type Voltage Capacity Input Type R A B C D Unit kg lb km h mph km h mph mm in mm in mm in mm in mm in kg lb kW V AH 5HR 1500 8 10 2065 2798 1100 1400 1700 1200 2 7 48 280 3 220 380V CC CV FET 305Ý127 5 00 8 8PR 4000 8 10 1565 2050 1100 1400 1200 1250 ą ą ą ą ą ą ą 4 00 8 15P 7 40T 7 1 15P 7 2 40T 7 ...

Page 43: ... Battery weight Max Battery weight Connector CE spec Electrolyte V mm kg kg 48V Unit Specification 965 380 550 445 720 SB 350 Refined dilute sulfuric acid Item Model Type Dimension Current limit Communication mm A Unit Drive motor controller PMC 1274 MOSFET 229 178 81 350 CAN Motor Motor 2 2 Charger 4 Item Type Battery capacity for charge V AH hr Unit 48V 450 520 5 Specification Triple phase 410 S...

Page 44: ...sure Rated flow Displacement kgf cm2 lpm cc rev 175 22 7 62 Unit Specification Drive unit 8 Item Max drive input Max wheel load Gear ratio Weight without fluid Oil quantity kW kg lb kg lb U S Âqt 5 0 750 1653 20 125 28 5 62 8 1 6 1 7 Unit Specification S Steering hydraulic motor 6 Item Model Max oil flow Displacement Max pressure Connector size min cc bar OMR 125 NA 60 125 7 175 PF 1 2 Unit Specif...

Page 45: ...eumatic solid Non marking 2 5 00 8 8PR 5 00 8 4 00 8 Front Rear B Brake 11 Parking brake Item Type Parking lever stroke Parking cable stroke Ratchet 40mm 16mm Specification 12 Item Type WÝLÝT Area New Repair limit Brake shoe Brake drum diameter Center brake 40Ý110Ý5mm 1 6Ý4 3Ý0 2in 44cm2 6 8in2 120mm 4 7in 117mm 4 6in 10 15mm 0 4 0 6in Less than 5 0m 197in Less than 2 0m 79in Specification Brake p...

Page 46: ...c oil tank mounting bolt Drive unit mounting bolt nut Rear axle mounting bolt nut Front wheel mounting nut Rear wheel mounting nut Seat mounting bolt Head guard mounting bolt M10Ý1 5 M 8Ý1 25 M 8Ý1 25 M10Ý1 5 M10Ý1 5 M 8Ý1 25 M18Ý2 5 M14Ý2 0 M16Ý1 5 M12Ý1 5 M 8Ý1 25 M12Ý1 75 6 9Ü1 4 2 0Ü0 2 3 7Ü0 7 4 0Ü0 5 4 0Ü0 5 2 5Ü0 5 41Ü3 20Ü2 0 20 5Ü1 5 10Ü1 0 2 5Ü0 5 12 8Ü3 0 49 9Ü10 1 14 4Ü1 4 26 8Ü5 1 28 ...