Hyundai 15P-7 Manual

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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

CONTENTS

Table of Contents

Summary of Contents for Hyundai 15P-7

Page 1: Table Of Contents
CONTENTS 1. GENERAL SAFETY RULES 1. Daily inspection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1 2.
Page 2 4. Daily maintenance checks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-4 5.
Page 3 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.
Page 4 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.
Page 5 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.
Page 6 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.
Page 7 GUIDE 1. DIRECTION The direction of this machine indicate forward, Front backward, right and left when machine is in the travelling direction. Right Left Rear BP157OM01 2. SERIAL NUMBER Inform following when you order parts or the machine is out of order. MACHINE SERIAL NUMBER It's shown of the front-left side of the frame.
Page 8: General Safety Rules
1. GENERAL SAFETY RULES 1. DAILY INSPECTION 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.
Page 9: Do's And Don'ts
2. DO'S AND DON'TS Do watch for pedestrians. D35AOM03 Do wear safety equipment when required. D35AOM05 Don't mix drugs or alcohol with your job. D35AOM02 Don't block safety or emergency equipment. D35AOM04 Don't smoke in NO SMOKING areas or when charging. D35AOM06...
Page 10 Don't operate the truck outdoors in rainy day. D35AOM031 Don't perform battery charging service in the room without adequate ventilation. D35AOM032 1-2-1...
Page 11: Seat Belts
3. SEAT BELTS Always buckle up for the machine equipped with safety belt. B207OM09 Seat belts can reduce injuries. B207OM10...
Page 12: No Riders
4. NO RIDERS The operator is the only one who should be on a battery tractor. BP157OM11...
Page 13: Pedestrians
5. PEDESTRIANS 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.
Page 14: Operator Protection
6. OPERATOR PROTECTION Always keep your body within the confines of the tractor. Always buckle up for the machine Seat belt equipped with safety belt. BP157OM16...
Page 15: Loading And Unloading By Crane
7. LOADING AND UNLOADING BY CRANE 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.
Page 16: Know Your Tractor
2. KNOW YOUR TRACTOR 1. GENERAL LOCATIONS LAYOUT HYUNDAI 1/10h BP157GEN01 Seat Emergency switch 11 Battery Steering wheel Start switch 12 Hook Rear view mirror Head lamp 13 Battery cover Parking brake lever Front wheel 14 Flasher lamp Monitor panel...
Page 17: Safety Plates And Decals
2. SAFETY PLATES AND DECALS SAFETY PLATE BP157OM56 BR147OM60...
Page 18: Instruments And Controls
3. INSTRUMENTS AND CONTROLS HYUNDAI 1/10h BP157OM62 Monitor panel Direction control lever Emergency switch Accelerator pedal Start switch Brake pedal Parking brake lever Steering wheel Flasher, head lamp switch Famaliarize yourself with the controls and follow safe operating procedures.
Page 19: Instruments Panel
4. INSTRUMENT PANEL HYUNDAI 1/10h BP157OM63 Hour meter Drive motor brush warning lamp Battery discharge indicator Seat switch indicator Parking brake indicator Diagnostic/service warning lamp Sequence fault warning lamp...
Page 20: Indicator Symbols
5. INDICATOR SYMBOLS HOUR METER 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 1/10h starting switch is at the ON position. BP157OM66 BATTERY DISCHARGE INDICATOR The state of battery discharge is indicated by 10 segments on...
Page 21 B15AOM70 DIAGNOSTIC/SERVICE WARNING LAMP 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 glimmering. B15AOM74...
Page 22: Operating Switches And Levers
6. OPERATING SWITCHES AND LEVERS EY SWITCH Power is supplied to the control circuit through this switch, which is placed on OFF ON clockwise. OFF : The Key can be removed or inserted and power is turned off. ON : Both control circuits for hydraulics and running can be activated.
Page 23 PARKING BRAKE LEVER Position Parking brake is applied and front wheel is locked. Position Parking brake is released. Before the tractor starts, confirm the parking brake is released position. BP157OM79 CCELERATOR PEDAL This pedal is used to vary running speed, which depends upon how far the pedal is depressed.
Page 24 SEAT SWITCH 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 EMERGENCY SWITCH Use for parking or loading machine. If the switch is left ON for a long time, the battery may be discharged.
Page 25: Seat Adjustment
7. SEAT ADJUSTMENT The seat adjustment lever is located on the front side under the seat. To unlock, pull the lever up and adjust the seat so that all controls may be comfortably reached. Then release the lever. Be sure that the seat locking mechanism is engaged. The seat mounting base provides an 3 inch fore-and-aft adjustment of its slide.
Page 26: Operating Procedures
Check of steering system Check that the steering wheel has no play. OPERATION Parking brake Starting/Travelling/Stopping With the direction control lever placed to HYUNDAI 1/10h Start key the neutral position, make sure the parking brake is located at the operating position.
Page 27 P P RECAUTIONS ON OPERATION Red zone Check of battery capacity If the level meter indicates the red zone HYUNDAI during heavy load operations such as starting, full-load travelling, hill-climbing, 1/10h even the battery needs not to be...
Page 28: Battery And Charger
4. BATTERY AND CHARGER 1. BATTERY CHARGING The charger is of the automatic type so that only requirement for charging is to insert the plug, there being no need for BATTERY CHARGER maintaining watch. BATTERY CHARGER MONITOR AC IN CHARGE LEVEL FLOAT EQUAL ERROR...
Page 29 INSTALLATION OF THE CHARGER Place for installation Install the charger at a place with good ventilation, no excessive temperature, low humidity and little dust. For the primary of the transformer, use the taps corresponding to the power voltage difference. For example, 218V(measured value)-220V(primary).
Page 30: Battery Handling
2. BATTERY HANDLING Change(remove) or service storage batteries only in an area designated for this purpose. Be sure this area has provisions to flush and neutralize spillage, to ventilate fumes from gassing batteries and for fire protection. This area should be equipped with material-handling tools designed for removing and replacing batteries, including a conveyor or overhead hoist.
Page 31: Battery Removal From Tractor
3. BATTERY REMOVAL FROM TRACTOR When the spare battery is used for continuous operation or it is required to check the battery, motor, etc., remove the battery through the following procedure: Disconnect the battery connector. BP157OM17 Open the battery cover. Battery cover Seat...
Page 32 NOTICES Charge the battery through removing the battery connector and connecting the charging connector of the stationary charger to the battery connector. Charger BATTERY CHARGER BATTERY CHARGER MONITOR AC IN CHARGE LEVEL FLOAT EQUAL ERROR RESET EQUAL S/W MANUAL STOP SWITCH BP157OM21 Be sure to open the battery cover during...
Page 33: Electric Tractor Battery Maintenance
4. ELECTRIC TRACTOR BATTERY MAINTENANCE BATTERY SERVICE AREA B15AOM128 Battery charging and installations must be located in areas designated for that purpose. These areas must be kept free of all non-essential combustible materials. Facilities must be provided for : Flushing spilled electrolyte. Fire protection.
Page 34: Battery Cleaning And Care
5. BATTERY CLEANING AND CARE AVOID OVER-DISCHARGE If used until the vehicle can no longer run, battery life will be shortened. If the battery capacity indicator's red lamps turns on at on load lift, stop operation and charge the battery without delay. B15AOM137 INFLAMMABLE In any case, keep fire away from the battery...
Page 35: Maintenance And Inspection
5. MAINTENANCE AND INSPECTION 1. BODY DRIVE WHEELS Pay constant caution to see that the set bolts of the power axle are not loosened. Make sure that the wheel tightening nuts are not loosened. When tightenting the nuts, be sure to tighten the nuts located at diagonal position scquentially so that they should not be tightened in deviant way.
Page 36: Electric System
FET unit is possibly defective. Since the FET unit is assembled in extremely precise way and adjusted, do not attempt to disassemble the unit unnecessarily. When such disassembling is necessary, be sure to make contact with HYUNDAI service shop.
Page 37: Major Component Location
3. MAJOR COMPONENT LOCATIONS Use the illustration below to locate components included in the PM procedures. 21 22 BP157OM113 Head lamp Hydraulic oil tank 17 Steering hyd motor Horn 10 Accelerator 18 Brake pedal Front wheel 11 Brake system 19 Drive motor Steering wheel 12 Flasher lamp 20 Harness...
Page 38: Daily Maintenance Checks
4. DAILY MAINTENANCE CHECKS The PM intervals depend on hour meter records of operation. PM interval A : 8 hours or daily B : 50 hours or every week(Typical PM interval) C : 250 hours or every 1 months D : 1000 hours or every 6 months E : 2000 hours or every year Daily maintenance checks Check truck for obvious damages and leaks.
Page 39 5 5 . PERIODIC MAINTENANCE CHECKS The PM intervals depend on hour meter records of operation. PM interval A : 8 hours or daily B : 50 hours or every week(Typical PM interval) C : 250 hours or every 1 months D : 1000 hours or every 6 months E : 2000 hours or every year Periodic checks and planned maintenance (PM)
Page 40: Lubrication
6. LUBRICATION Since the life of vehicle is dependent upon the quality of lubrication, be sure to perform the lubrication with utmost care so that the tractor will not fall in trouble due to insufficient or improper lubrication oil. In supplying the oil, be sure to 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 32 and that of low viscosity in winter(for normal temperature of under 0 C).
Page 41: New Machine Oils
: American Petroleum Institute SAE : Society of Automotive Engineers ISO : International Organization for Standardization 8 8 . RECOMMENDED LUBRICANTS Capacity (U.S. gal Ambient temperature C( F) Service Kind of 15P-7 point fluid 40T-7 (-4) (14) (32) (50) (68) (86)
Page 42: Specifications
6. SPECIFICATIONS 1. SPECIFICATIONS DIMENSIONS 1) 15P-7 BP157SP01 (2) 40T-7 BP157SP01 Item Unit 15P-7 40T-7 Capacity kg(lb) 1500 4000 Loaded km/h(mph) Travel speed Unloaded km/h(mph) mm(in) 2065 1565 Min. turning radius mm(in) 2798 2050 Overall length mm(in) 1100 1100 Overall width...
Page 43 2) 2) SPECIFICATION FOR MAJOR COMPONENTS SPECIFICATION FOR MAJOR COMPONENTS (1) (1) Controller Controller Item Unit Drive motor controller Model PMC 1274 Type MOSFET 229×178×81 Dimension Current limit Communication (2) (2) Motor Motor Item Unit Drive motor Power steering motor Model EF5-4003 21HB-72090...
Page 44 Power steering pump Item Unit Specification Type Fixed displacement gear pump Capacity cc/rev Maximum operating pressure Rated speed(max/min) 3600/900 teering hydraulic motor Item Unit Specification Model OMR 125 NA Max oil flow /min Displacement 125.7 Max pressure Connector size PF 1/2 Steering unit Item Unit...
Page 45 W W heels Rear Item Front Type Cushion, Urethane, Non-marking Pneumatic(solid), Non-marking Quantity HBP15-7 5.00-8-8PR(5.00-8) Wheel HBT40-7 305 127 4.00-8 (10) Steering Item Specification Type Full hydraulic, power steering Steering Steering angle to both right and left angle, respectively (11) rake Item Specification...
Page 46 TIGHTENING TORQUE FOR MAJOR COMPONENTS Items Size kgf m lbf ft M10 1.5 6.9 1.4 49.9 10.1 Hyd pump motor mounting bolt Electric system M 8 1.25 2.0 0.2 14.4 1.4 Drive motor mounting bolt M 8 1.25 3.7 0.7 26.8 5.1 Hydraulic pump mounting bolt M10 1.5...

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40t-7