Table of Contents
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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. Fork safety ---------------------------------------------------------------------------------------------------------------- 1-7
8. Pinch points -------------------------------------------------------------------------------------------------------------- 1-8
9. Travel ------------------------------------------------------------------------------------------------------------------------- 1-9
10. Grades, ramps, slopes and inclines ----------------------------------------------------------------------- 1-10
11. Tip over --------------------------------------------------------------------------------------------------------------------- 1-11
12. Surface and capacity ----------------------------------------------------------------------------------------------- 1-13
13. Parking ---------------------------------------------------------------------------------------------------------------------- 1-14
14. Lifting, jacking and blocking ------------------------------------------------------------------------------------ 1-15
15. Loading and unloading by crane ---------------------------------------------------------------------------- 1-20
1. Loose loads -------------------------------------------------------------------------------------------------------------- 2-1
2. Long and wide loads ------------------------------------------------------------------------------------------------ 2-2
3. Rear swing ---------------------------------------------------------------------------------------------------------------- 2-2
4. Low overhead clearance ----------------------------------------------------------------------------------------- 2-3
5. Fast turns and high loads ---------------------------------------------------------------------------------------- 2-3
6. Drop-offs ------------------------------------------------------------------------------------------------------------------- 2-4
7. Right-angle stacking ------------------------------------------------------------------------------------------------ 2-4
8. Chain slack --------------------------------------------------------------------------------------------------------------- 2-5
9. Pallets and skids ------------------------------------------------------------------------------------------------------ 2-5
10. Caution for electrical lines --------------------------------------------------------------------------------------- 2-6
11. Solid tire -------------------------------------------------------------------------------------------------------------------- 2-7
1. General locations ----------------------------------------------------------------------------------------------------- 3-1
2. Data/safety plates and decals --------------------------------------------------------------------------------- 3-2
3. Instruments and controls ----------------------------------------------------------------------------------------- 3-5
4. Instruments panel ---------------------------------------------------------------------------------------------------- 3-6
5. Operating switches and levers ------------------------------------------------------------------------------- 3-19
6. Seat adjustment ------------------------------------------------------------------------------------------------------- 3-23
7. Battery compartment access --------------------------------------------------------------------------------- 3-24
CONTENTS
CONTENTS
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Table of Contents
Related Manuals for Hyundai 15BT-9U
Summary of Contents for Hyundai 15BT-9U
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Page 1: Table Of Contents
CONTENTS CONTENTS 1. GENERAL SAFETY RULES 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. - Page 2 4. DAILY SAFETY INSPECTION 4. DAILY SAFETY INSPECTION 1. Inspecting your truck ----------------------------------------------------------------------------------------------- 4-1 2. Visual checks ----------------------------------------------------------------------------------------------------------- 4-2 3. Functional checks ---------------------------------------------------------------------------------------------------- 4-3 4. Concluding the inspection ---------------------------------------------------------------------------------------- 4-3 5. OPERATING PROCEDURES 5. OPERATING PROCEDURES 1. Before operating the truck -------------------------------------------------------------------------------------- 2.
- Page 3 14. Electric truck battery maintenance ------------------------------------------------------------------------ 7-17 15. Battery handling ------------------------------------------------------------------------------------------------------ 7-18 16. Battery charging ------------------------------------------------------------------------------------------------------ 7-19 17. Battery removal from truck ------------------------------------------------------------------------------------- 7-21 18. Battery cleaning and care -------------------------------------------------------------------------------------- 7-23 19. Lithum-ion battery --------------------------------------------------------------------------------------------------- 7-23-1 20. Lithum-ion battery charger -------------------------------------------------------------------------------------- 7-23-5 21.
- Page 4 HYUNDAI fork lift trucks are built to take hard work, but not abuse. They are built to be dependable, but they are only safe and efficient as the operator and the persons responsible for maintaining them. Do not make any repairs to this truck unless you have been trained in safe fork lift truck repair procedures and are authorized by your employer.
- Page 5 HYUNDAI welcomes you to the growing group of professionals who own, operate and maintain HYUNDAI fork lift trucks. 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 fork lift truck.
- Page 6 ※The descriptions and specifications included in this manual were in effect at the time of printing. HYUNDAI reserves the right to make improvements 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 7 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 fork lift truck's features, operation, or manuals.
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Page 8: Safety Labels
Model name 14 EMC 25 Fork Tilt Side cover LH 15 Caution BAT.Handling 26 Side Shift Side cover RH 16 Safety Warning 27 HYUNDAI Logo Warning O.H.G 17 Brake Fluid wet Tape Marking Hanger 18 Hook Seat Warning Mast Warning... - Page 9 2. DESCRIPTION 2. DESCRIPTION There are several specific warning labels on this machine please become familiarized with all warn- ing labels. Replace any safety labels if those are damaged, or missing. MAST WARNING MAST WARNING (ltem 6) This warning label is positioned on the both side of the mast.
- Page 10 4) 4) HANGER HANGER (Item 5) This warning label is positined on the Counter Weight. Refer to page 1-20 for safe loading pro- Refer to page 1-20 for safe loading pro- cedures. cedures. 15BT9UOM0005 BRAKE FLUID WET BRAKE FLUID WET(Item 17) This warning label is located on the left side of dashboard.
- Page 11 7) 7) BATTERY HANDLING BATTERY HANDLING (Item 15) This battery handling is located on the left side of the bonnet. Refer to page 7-22 for a safe battery Refer to page 7-22 for a safe battery removal. removal. ※ Open the battery cover when charging. Open the battery cover when charging.
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Page 12: Warning Safety
8) WARNING SAFETY 8) WARNING SAFETY (Item 16) This warning safety is located on the left side of the dashboard cover. 15BT9UOM0009... - Page 13 GUIDE GUIDE 1. DIRECTION 1. DIRECTION The direction of this machine indicate forward, Front backward, right and left when machine is in the travelling direction. Left Right Rear 15BT9UOM0010 2. SERIAL NUMBER 2. SERIAL NUMBER Inform following when you order parts or the machine is out of order. 1) 1) MACHINE SERIAL NUMBER MACHINE SERIAL NUMBER...
- Page 14 4. WHOLE BODY VIBRATION 4. WHOLE BODY VIBRATION The whole body vibration level is measured according to standard EN13059 which contains The whole body vibration level is measured according to standard EN13059 which contains specific test criteria (load, speed, roadway surface, etc.). Worksite vibration levels may vary specific test criteria (load, speed, roadway surface, etc.).
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Page 15: General Safety Rules
1. GENERAL SAFETY RULES 1. DAILY INSPECTION At the beginning of each shift, inspect your battery fork lift truck and fill out a check, maintenance and lubrication table. Check for damage and maintenance problems. Have repairs made before you operate the battery fork lift truck. -
Page 16: Do's And Don'ts
2. DO'S AND DON'TS Do watch for pedestrians. 15BT9UOM0101 Do wear safety equipment when required. 15BT9UOM0102 Don't mix drugs or alcohol with your job. 15BT9UOM0103 Don't block safety or emergency equipment. 15BT9UOM0104 Don't smoke in NO SMOKING areas or when charging. 15BT9UOM0105... - Page 17 Don't operate the truck outdoors in rainy day. 15BT9UOM0106 Don't perform battery charging service in the room without adequate ventilation. 15BT9UOM0107 1-2-1...
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Page 18: Seat Belts
3. SEAT BELTS Always wear a seat belt when operate the truck. 15BT9UOM0108 Seat belts can reduce injuries. 15BT9UOM0109... -
Page 19: No Riders
4. NO RIDERS The operator is the only one who should be on a truck. 15BT9UOM0110 Never transport personnel on the forks of a lift truck. 15BT9UOM0111... -
Page 20: 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. 15BT9UOM0112 Watch for people in your work area even if your battery tractor has warning lights or alarms. -
Page 21: Operator Protection
6. OPERATOR PROTECTION Keep under the overhead guard. Always keep your body within the confines of the truck. 15BT9UOM0115... -
Page 22: Fork Safety
7. FORK SAFETY Never allow anyone to walk under raised forks. 15BT9UOM0116 There is special equipment to raise people for overhead work. Don't use Fork lift trucks to lift personnel. 15BT9UOM0117... -
Page 23: Pinch Points
8. PINCH POINTS Keep hands, feet and legs out of the mast. 15BT9UOM0118 Don't use the mast as a ladder. 15BT9UOM0119 Never try to repair the mast, carriage, chain, or attachment yourself. Always get a trained mechanic. 15BT9UOM0120... -
Page 24: Travel
9. TRAVEL Travel with the load near the floor/ground with mast tilted back to cradle the load whenever possible. Never lift or lower the load when the truck is in motion. 15BT9UOM0121 When handling bulky loads that restrict your vision operate your truck in reverse to improve visibility. -
Page 25: Grades, Ramps, Slopes And Inclines
10. GRADES, RAMPS, SLOPES AND INCLINES Never turn on a grade, either loaded or unloaded. UNLOADED - Forks downgrade 15BT9OM0124 Loaded - Forks upgrade 15BT9UOM0125 1-10... -
Page 26: Tip Over
11. TIP OVER LATERAL TIP OVER Lateral tip over can occur with a combination of speed and sharpness of turn. This combination will exceed the stability of the truck. This condition is even more likely with an unloaded truck. With the load or mast raised, lateral tip over can occur while turning and/or braking when traveling in reverse or accelerating and turning while traveling... - Page 27 WHAT TO DO IN CASE OF A TIP OVER If your truck starts to tip over, Do not jump. Brace yourself as illustrated right. 1 Make sure your seat belt is fastened securely, if the truck is equipped with seat belt.
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Page 28: Surface And Capacity
12. SURFACE AND CAPACITY Avoid these conditions. They can cause a truck to tip over or lose traction for braking or driving. Know the weight of your truck and load. Especially when using elevators, Know the capacity of the elevator you intend to use. -
Page 29: Parking
13. PARKING Never park on a grade. 15BT9UOM0130 Always come to a complete stop before leaving truck. Be sure travel control is in NEUTRAL. 15BT9UOM0131 Lower forks fully to floor and tilt forward. 15BT9UOM0132 Turn key to OFF position. 15BT9UOM0133 1-14... -
Page 30: Lifting, Jacking And Blocking
14. LIFTING, JACKING AND BLOCKING Lifting or jacking any large piece of equipment such as forklift truck presents obvious hazards. It must be done with great care and forethought. SAFE PARKING Before working on truck : Park truck on a hard, level and solid surface, such as a concrete floor with no gaps or breaks. Put mast in vertical position and fully lower the forks or attachment. - Page 31 Tilt mast fully forward. This raises the drive wheels off the floor. Release the tilt control lever and turn engine OFF. 15BT9UOM0136 Insert blocking under the frame behind the drive wheels or slip wheel cradles under the drive wheels. If using blocking, check for safe clearance between drive wheels and floor and blocks.
- Page 32 BLOCKING THE MAST IN RAISED POSITION This procedure is used to safely provide clearance for access from the front of truck to components on or near the drive axle. Illustrations show mast with forks removal, however, fork removal is not necessary.
- Page 33 RAISING REAR OF TRUCK The truck may be raised at the rear by jacking and blocking under the center of the frame member at either the front or rear steer axle mounting, or under the center section of the steering axle. Refer to truck data plate for truck weights.
- Page 34 Put the jack under side frame near the center of the truck. Be sure to put the jack squarely and fully under the main side structure of the frame. Do not put the jack under the outer covers which enclose the fuel and hydraulic sump tanks.
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Page 35: Loading And Unloading By Crane
15. LOADING AND UNLOADING BY CRANE Check the specification of the truck when you are going to hoist the truck. Before loading the truck, battery must be removed. Refer to page 7-21 for a safe battery removal. 15BT9UOM0143 Use long wire rope and stay to keep the distance with the machine as it should avoid touching with Stay Wire rope... -
Page 36: Operating Hazards
2. OPERATING HAZARDS 1. LOOSE LOADS Loose or unbalanced loads are danger- ous. Observe these precautions. Never carry loose or uneven material. 15BT9UOM0200 Place the wide loads in the middle of the forks. 15BT9UOM0201 Stack and band loose material. 15BT9UOM0202... -
Page 37: Long And Wide Loads
2. LONG AND WIDE LOADS With long or wide loads, you need more room. So slow down and watch your clearance. When extra-long material makes it necessary to travel with the load elevated, do so with extreme care and be alert to load end-swing when turning. -
Page 38: Low Overhead Clearance
4. LOW OVERHEAD CLEARANCE Know the height of your truck, with and without a load. Check your clearances. Keep the load low and tilted back. 15BT9UOM0205 Watch overhead clearance : Moving into overhead structures can tip a truck over, or spill a load. 15BT9UOM0206 5. -
Page 39: Drop-Offs
6. DROP-OFFS To avoid these hazards, you must : Talk to the truck driver yourself : make sure the driver does not move the trailer until you are done. Apply trailer brakes. Use wheel chocks. Use trailer-to-dock locking system if available. -
Page 40: Chain Slack
8. CHAIN SLACK Slack chains mean rail or carriage hang- up. Raise the forks before you move, or broken chains can result. 15BT9UOM0212 15BT9UOM0213 9. PALLETS AND SKIDS Do not move or store materials on damaged pallets or skids. Items can fall through them causing severe injury or death. -
Page 41: Caution For Electrical Lines
10. CAUTION FOR ELECTRICAL LINES When moving the machine with the mast raised, watch out electrical lines over the machine. The operation near the electrical lines is very dangerous. Operate within safe working permitted as below. Supply voltage Min safe separation 6.6 kV 3 m (10 ft) 15BT9UOM0215... -
Page 42: Solid Tire
11. SOLID TIRE 11. SOLID TIRE Do not travel more than 25 km/hr (16 mph). Do not travel further than 8 km (5 miles) in an hour. Do not drive on the road for automobile. After continuous traveling radiates enough the heat of tire. (e.g. 1 hour radiation of the heat after 2 hours continuous traveling) Our warranty does not cover any damages caused by excessive driving. -
Page 43: Know Your Truck
3. KNOW YOUR TRUCK 3. KNOW YOUR TRUCK 1. GENERAL LOCATIONS 1. GENERAL LOCATIONS 15BT9UOM0301 TRUCK TYPE : Electric Sit-Down Rider, 48 Volt. Drive axle, tires and wheels Steering wheel Steering axle, tires and wheels Directional control lever Overhead guard Mast Seat Carriage and backrest... -
Page 44: Data/Safety Plates And Decals
Truck serial number An identification number assigned to this particular truck and should be used when requesting information or ordering service parts for this truck from your authorized HYUNDAI dealer. The serial number is also stamped on the frame. (3) (3) - Page 45 2) 2) OPERATOR SAFETY WARNING DECAL OPERATOR SAFETY WARNING DECAL 15BT9UOM0303 Safety and warning decals are placed in conspicuous locations on the Safety and warning decals are placed in conspicuous locations on the truck to remind you of essential procedures or to prevent you from truck to remind you of essential procedures or to prevent you from making an error that could damage the truck or possibly cause personal making an error that could damage the truck or possibly cause personal...
- Page 46 Mast warning decal Mast warning decal This safety decal is placed on the mast to warn of the danger of injury from movement between rails, chains, sheaves, fork carriage, and other parts of the mast assembly. Do not climb on or reach into the mast. Personal injury will result if any part of your body is put between moving parts of the mast.
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Page 47: Instruments And Controls
3. INSTRUMENTS AND CONTROLS 3. INSTRUMENTS AND CONTROLS 15BT9UOM0307 Steering wheel 11 Head lamp switch Tilt fingertip lever(opt) Key switch Lift fingertip lever(opt) 12 Display Turn signal lever Emergency switch 13 Accelerator pedal Tilt lever 14 Brake pedal Beacon lamp switch Lift lever 10 Rear work lamp switch 15 Directional control lever... -
Page 48: Instruments Panel
4. INSTRUMENT PANEL 4. INSTRUMENT PANEL (15BT-9U : ~#303, 18BT-9U : ~#449, 20BT-9U : ~#782) (15BT-9U : ~#303, 18BT-9U : ~#449, 20BT-9U : ~#782) 1) 1) STRUCTURE STRUCTURE The instrument panel (Display) has six built-in red LED, which provide the operator with an easy information about the status of some truck devices. - Page 49 2) 2) WARNING LAMP WARNING LAMP (1) (1) Brake oil level warning lamp rake oil level warning lamp This LED lights when measured level of brake oil stored in reservoir tank is below the minimum acceptable mark. 15BT9UOM0309 (2) (2) Wrench warning lamp Wrench warning lamp This LED lights when an electric device (controller, motor, cable,...
- Page 50 3) 3) BUTTON BUTTON These buttons are used to select or change the menu and input value of the LCD function and display menu. (1) (1) Up button Up button Press to select upward move. 15BT9UOM0315 (2) (2) DOWN/TURTLE DOWN/TURTLE button button Press to select downward move.
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Page 51: Lcd Function
4) 4) LCD FUNCTION LCD FUNCTION 15BT9UOM0321 Current time Hour meter Turtle mode Wheel position and running direction Truck speed pointer Power mode Speed level BDI (Battery Discharge Indicator) Truck speed 10 Load weight (option) Current time Current time The number shows the current time according to the setting, which can be changed by display setting at page 3-11. - Page 52 Truck speed Truck speed The truck speed is shown in number. The unit can be km/h or mph according to the display setting (see 3-11 page). Hour meter Hour meter The number shows the hours worked. The letter present beside the hour meter number shows which hour meter is displayed.
- Page 53 5) 5) HOW TO SET THE DISPLAY MENU HOW TO SET THE DISPLAY MENU 15BT9UOM0322 3-11...
- Page 54 15BT9UOM0323 3-12...
- Page 55 4. INSTRUMENT PANEL : DISPLAY (15BT-9U : #304~, 18BT-9U : #450~, 20BT-9U : #783~) 4. INSTRUMENT PANEL : DISPLAY (15BT-9U : #304~, 18BT-9U : #450~, 20BT-9U : #783~) 1) 1) STRUCTURE STRUCTURE The instrument panel (display) has six built-in red LED, which provide the operator with an easy information about the status of some truck devices.
- Page 56 2) 2) WARNING LAMP WARNING LAMP (1) (1) Brake oil level warning lamp rake oil level warning lamp This LED lights when measured level of brake oil stored in reservoir tank is below the minimum acceptable mark. 25B9U0M0309 (2) (2) Wrench warning lamp Wrench warning lamp This LED lights when an electric device (controller, motor, cable,...
- Page 57 3) 3) BUTTON BUTTON These buttons are used to select or change the menu and input value of the LCD function and display menu. (1) (1) Up button Up button Press to select upward move. 25B9U0M0315 (2) (2) DOWN/TURTLE DOWN/TURTLE button button Press to select downward move.
- Page 58 4) 4) LCD FUNCTION LCD FUNCTION 25B9U0M0321-1 Current time BDI (Battery Discharge Indicator) Turtle mode Hour meter Truck speed pointer Load weight (option) Speed level Wheel position and running direction Truck speed 10 Power mode Current time Current time The number shows the current time according to the setting, which can be changed by display setting at page 7-58.
- Page 59 Truck speed Truck speed The truck speed is shown in number. The unit can be km/h or mph according to the display setting (see 7-66 page). Hour meter Hour meter The number shows the hours worked. The letter present beside the hour meter number shows which hour meter is displayed.
- Page 60 5) 5) HOW TO SET THE DISPLAY MENU HOW TO SET THE DISPLAY MENU ▶ ▶ ▶ ▶ ▶ 3-18...
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Page 61: Operating Switches And Levers
5. OPERATING SWITCHES AND LEVERS 5. OPERATING SWITCHES AND LEVERS 1) 1) KEY SWITCH KEY 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 ①... - Page 62 FLASHER SWITCH(OPTION-IF FINGER TIP INSTALLED) FLASHER SWITCH(OPTION-IF FINGER TIP INSTALLED) Left turn Right turn 15BT9UOM0326 4) 4) HORN BUTTON HORN BUTTON When the button (①) is pressed, the horn will sound. 15BT9UOM0327 5) 5) ACCELERATOR PEDAL ACCELERATOR PEDAL This pedal is used to vary running speed, which depends upon how far the pedal is depressed.
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Page 63: Seat Switch
8) 8) LIFT LEVER / LIFT FINGERTIP LIFT LEVER / LIFT FINGERTIP (OPTION) (1) (1) LIFT LIFT ·Lever type Lift PULL the lever (fingertip) BACK to LIFT the load. Lower (2) (2) LOWER LOWER PUSH the lever (fingertip) FORWARD to LOWER the load. (3) (3) HOLDING HOLDING... -
Page 64: Head Lamp Switch
EMERGENCY EMERGENCY SWITCH SWITCH When pressing the emergency switch downward the electric circuit is broken, all electrical function switch is off. 15BT9UOM0334 EMERGENCY EMERGENCY SWITCH(OPTION, IF FINGER TIP INSTALLED) SWITCH(OPTION, IF FINGER TIP INSTALLED) HEAD LAMP SWITCH HEAD LAMP SWITCH This switch is used to operate head lamps. -
Page 65: Seat Adjustment
6. SEAT ADJUSTMENT 6. SEAT ADJUSTMENT 1) 1) SEAT ADJUST MENT SEAT ADJUST MENT The seat adjustable to fit the contours of the operator's body. It will reduce operator fatigue due to long works hours and enhance work efficiency. Grammer seat Grammer seat (1) (1) Forward/Backward adjustment (A) -
Page 66: Battery Compartment Access
7. BATTERY COMPARTMENT ACCESS 7. BATTERY COMPARTMENT ACCESS The combination seat deck/battery compartment cover pivots mast to provide access to the battery compartment. You must tiIt the steering column & lever You must tiIt the steering column & lever ※ forward before raising the cover. -
Page 67: Daily Safety Inspection
Do not make repairs yourself unless you are trained in fork lift truck repair procedures and authorized by your employer. Have a qualified mechanic make repairs using genuine HYUNDAI or HYUNDAI- approved parts. Do not operate a truck if it is in need of repair. If it is in an unsafe condition, remove the key and report the condition to the proper authority. -
Page 68: Visual Checks
2. VISUAL CHECKS First, perform a visual inspection of the truck and its major components : Walk around your lift truck and take note of obvious damage that may have been caused by operation during the last shift. Check that all capacity, safety, and warning plates or decals are attached and legible. Check that the battery is installed and secured in position correctly. -
Page 69: Functional Checks
3. FUNCTIONAL CHECKS Check the operation of the truck as follows. Before performing these checks, familiarize yourself with the operating procedures in Section Test warning devices, horn, lights, and other safety equipment and accessories. With the truck on, check the diagnostic display, or the hour meter and battery discharge indicator (depending on which truck you have). -
Page 70: Operating Procedures
5. OPERATING PROCEDURES 1. BEFORE OPERATING THE TRUCK Be sure that you have read and understand the information in this Operator's Manual and are trained and authorized before operating the lift truck. This equipment can be dangerous if not used properly. Safe operation is the responsibility of the operator. -
Page 71: Adjusting The Seat
3. ADJUSTING THE SEAT Adjust the seat to a comfortable position for you. Adjust the seat by moving and holding the release lever at the front edge of the seat. Put the seat in a position that will provide easy reach to all controls. Never adjust the driver's seat while the truck is moving, to avoid the possibility of loss of control and of personal injury. -
Page 72: Starting The Truck
4. STARTING THE TRUCK Before you start the truck, make sure that you have taken all the above mentioned precautions and that the directional control lever is in NEUTRAL. Also you must sit down on the seat before starting the truck. To start the truck, turn the key switch clockwise to the ON position. RUNNING Place the directional control lever on the FORWARD position (or the REVERSE... -
Page 73: Stopping And Parking
STOPPING AND PARKING Release the foot from the accelerator pedal beforehand and allow the speed to drop before stepping on the brake pedal. 15BT9UOM0507 When the vehicle is parked, return the directional control lever to the neutral. Directional Control Lever Neutral 15BT9UOM0508 Next, Confirm the parking brake is applied... -
Page 74: Controlling Speed
5. CONTROLLING SPEED With the directional control lever in FORWARD or REVERSE, put your foot on the accelerator pedal and push down smoothly until the truck is moving at the desired speed. 6. BRAKING To stop the truck, lift your foot from the accelerator pedal and put it on the brake pedal. Push down on the brake pedal in a smooth, firm motion until the truck is stopped. -
Page 75: Operating Safely
8. OPERATING SAFELY Safe operation is the responsibility of the operator. Watch where you are going. Don’t go if you can’t see. Before driving, check all around to be sure that your intended path of travel is clear of obstructions and pedestrians. - Page 76 Travel with the fork carriage tilted back and raised only enough to fully clear the ground or obstacles. When the carriage(load) is in an elevated position the stability of the truck is reduced. Do not elevate the load except during stacking. Grades, ramps, and inclines.
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Page 77: Load Handling
9. LOAD HANDLING GENERAL Handle only loads that are within the truck rated capacity as shown on the nameplate. This rating specifies the maximum load that should be lifted. However, other factors such as special load handling attachments, load of a high center of gravity, or uneven terrain may dictate that the safe working load be less than the rated capacity. - Page 78 ADJUSTING THE LOAD FORKS The load forks are adjustable on the hanger, carriage. Forks should be spaced as far apart as the load will allow. Both forks should always be the same distance from the center of the fork carriage. To adjust the forks, raise the carriage slightly. Tilt the mast fully forward to reduce friction and make the fork slide easier.
- Page 79 TRAVELING WITH LOAD Travel with load or carriage as low as possible and tilted back. Never travel with the load or carriage raised (elevated) in a high position. Do not elevate the load except during stacking. Observe all traffic regulations and watch for other traffic, pedestrians, and safe clearances. Always look in the direction of travel.
- Page 80 PICKING UP AND MOVING LOADS When picking up a load from the ground, approach the load slowly and carefully align the truck square with the load. The forks should be adjusted to fit the load or pallet being handle and spread as wide as possible to provide good stability and balance.
- Page 81 STACKING To put a load on a stack Approach slowly and align the lift truck and load squarely with the stack. 15BT9UOM0515 Raise the load as the lift truck nears the stack. 15BT9UOM0516 Move forward slowly until the load almost touches the stack. The leading edge and sides of the load pallet should line up exactly with the near edge and side of the load or rack on which you are stacking.
- Page 82 To move a load from a stack Approach the stack carefully, truck lined up squarely with the load. With mast vertical, raise the forks to the correct height for freely engaging the load pallet. Adjust fork angle as necessary to fit squarely under the load.
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Page 83: Shut Down Procedure
10. SHUT DOWN PROCEDURE Always leave your lift truck in a safe condition. When you leave your truck, or park it, follow these safety rules Park in a safe area away from normal traffic. Never park on a grade. Never park in areas that block emergency routes or equipment, access to fire aisles, or stairways and fire equipment. -
Page 84: Emergency Towing
6. EMERGENCY TOWING 1. TOWING PRECAUTIONS If your lift truck becomes disabled but it can be moved freely on its own wheels without further damage, use the following procedures to tow it safely to a repair area. It is important for your safety and the care of your lift truck to use the proper equipment and carefully follow these recommendations for safe towing. -
Page 85: Towing Procedures
Replace it, when necessary, only with a genuine HYUNDAI replacement part). Use an approved, solid metal tow bar with towing couplers that connect to the towing pins in the counterweights. -
Page 86: Planned Maintenance
Specifications for selected components, fuel, lubricants, critical bolt torques, refill capacities, and settings for the truck are found in Section 8. If you need for more information on the care and repair of your truck, see you HYUNDAI dealer. -
Page 87: Planned Maintenance Intervals
The maintenance time intervals referred to in this manual relate to truck operating hours as recorded on the hourmeter, and are based on experience which HYUNDAI has found to be convenient and suitable under typical(normal or average) operating conditions. -
Page 88: Major Component Locations
5. MAJOR COMPONENT LOCATIONS Use the illustration below to locate components included in the PM procedures. 15BT9UOM0701 Mast Dash board 11 Seat Lift cylinder Frame 12 Steering wheel Carriage and backrest Steering axle 13 Overhead guard Forks Counterweight Drive unit 10 Battery cover... -
Page 89: Daily Maintenance Checks
6. DAILY MAINTENANCE CHECKS 6. DAILY MAINTENANCE CHECKS The PM intervals are depend on hour meter records of operation. Daily (or every 10 hours) maintenance check list Check truck for obvious damages and leaks. Check clean battery terminals. Check electrolyte level. Check capacity, warning plates and decals. -
Page 90: Periodic Maintenance Checks
Clean* Clean* replacement Hydraulic oil return filter parts Hydraulic tank suction strainer Hydraulic oil (conventional) Hydraulic oil (HYUNDAI genuine) 5000 hours Lift chain adjustment and wear. Check contactor. (Replace contactor tips if roughness is remarkable.) Brake fluid Harsh condition *... -
Page 91: Safe Maintenance Practices
Carefully read and understand these instructions and the specific maintenance procedures before attempting to do any repair work. When in doubt of any maintenance procedure, please contact your local HYUNDAI dealer. Powered industrial trucks can become hazardous if maintenance is neglected. Therefore, suitable maintenance facilities, trained personnel and procedures shall be provided. - Page 92 Parts, including tires are to be installed per the manufacturer's procedures. Always use genuine HYUNDAI or HYUNDAI-approved parts. When removing tires follow industry safety practices. Most importantly, deflate pneumatic tires completely prior to removal.
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Page 93: Maintenance Guide
9. MAINTENANCE GUIDE SUPPLYING BRAKE FLUID A hydraulically operated brake is employed. Check the level of brake fluid in the reservoir tank. When the level is low, refill. Do not mix with different kinds of brake fluid. Be careful not to allow external dust to enter through the reservoir cap vent hole and clog it. - Page 94 CHECKING OF HUB NUT TIGHTENING CONDITION Make sure that the hub nut is firmly tightened. T ightening and checking should be made in a diagonal order to prevent unbalanced tightening. (See the figure.) 15BT9UOM0705 GREASING UP Clean the following fittings with brushes or waste and apply grease to them. Be careful not to supply too much grease.
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Page 95: Fuse Replacement
CHECK FOR THE OIL LEVEL OF THE DRIVING GEAR CASE Check for the oil level by taking out the plug provided front side of the gear case. Drain plug Mag plug 15BT9UOM0706 EXTERNAL APPEARANCE CHECK OF THE VEHICLE Check for the external appearance of vehicles. If any defect is found immediately contact the service station. -
Page 96: Lift Chain Lubrication
HYUNDAI chain lubricant is recommended. It is easily sprayed on and provides superior lubrication. Heavy motor oil may also be used as a lubricant and corrosion inhibitor. -
Page 97: Visual Inspection
10. VISUAL INSPECTION First, perform a visual inspection of the lift truck and its components. Walk around the truck and take note of any obvious damage and maintenance problems. Check for loose fasteners and fittings. Check to be sure all capacity, safety, and warning plates or decals are attached and legible. NAMEPLATES AND DECALS : Do not operate a lift truck with damaged or lost decals and nameplates. - Page 98 FORKS Inspect the load forks for cracks, breaks, bending, and wear. The fork top surfaces should be level 10% of "A" is and even with each other. The height difference max. wear allowed between both fork tips refer to below table. Fork length Height difference Model...
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Page 99: Wheels And Tires
WHEELS AND TIRES Check the condition of the drive and steering wheels and tires. Remove objects that are embedded in the tread. Inspect the tires for excessive wear and breaks or chunking out. Check all wheel lug nuts or bolts to be sure none of them is loose or missing. -
Page 100: Checking The Hydraulic Fluid
11. CHECKING THE HYDRAULIC FLUID Check the hydraulic sump tank fluid level. Correct fluid level is important for proper system operation. Low fluid level can cause pump damage. Hydraulic fluid expands as its temperature rises. Therefore, it is preferable to check the fluid level at operating temperature (after approximately 30 minutes of truck operation). -
Page 101: Air Cleaning The Truck
13. AIR CLEANING THE TRUCK Always maintain a lift truck in a clean condition. Do not allow dirt, dust, lint or other contaminants to accumulate on the truck. Keep the truck free from leaking oil and grease. Wipe up all oil spills. Keep the controls and floorboards clean, dry and safe. -
Page 102: Electric Truck Battery Maintenance
14. ELECTRIC TRUCK BATTERY MAINTENANCE BATTERY BATTERY SERVICE SERVICE AREA AREA 15BT9UOM0715 Battery charging 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. -
Page 103: Battery Handling
15. 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 104: Battery Charging
16. 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 BATTERY CHARGER MONITOR maintaining watch . AC IN CHARGE LEVEL FLOAT EQUAL ERROR RESET EQUAL S/W... -
Page 105: Installation Of The Charger
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). Confirm the earth line of charging cable wire and make sure the earth line connects the earth of building. -
Page 106: Battery Removal From Truck
17. BATTERY REMOVAL FROM TRUCK 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. 15BT9UOM0707 Release the battery cover latch. 15BT9UOM0719 Pull the plunger and tilt the levers forward. - Page 107 4-1) Open the side door. (SBR Type, Option) Side door open 15BT9OM87 Remove the battery stopper. 15BT9UOM0722 Put down the battery with fork lift or chain block by hang up hook at 4 links which located in right and left of the battery. When installing the battery, follow the above steps in reverse order.
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Page 108: Battery Cleaning And Care
18. 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. 15BT9UOM0724 INFLAMMABLE In any case, keep fire away from the battery... - Page 109 Specifications for selected components, fuel, lubricants, critical bolt torques, refill capacities, and settings for the truck are found in Section 8. If you have need for more information on the care and repair of your truck, see your HYUNDAI dealer.
- Page 110 The maintenance time intervals referred to in this manual relate to truck operating hours as recorded on the hourmeter, and are based on experience which HYUNDAI has found to be convenient and suitable under typical(normal or average) operating conditions.
- Page 111 5. MAJOR COMPONENT LOCATIONS 5. MAJOR COMPONENT LOCATIONS Use the illustration below to locate components included in the PM procedures. 15BT9UOM0701 Mast Dash board 11 Seat Lift cylinder Frame 12 Steering wheel Carriage and backrest Steering axle 13 Overhead guard Forks Counterweight Drive unit...
- Page 112 6. DAILY MAINTENANCE CHECKS 6. DAILY MAINTENANCE CHECKS The PM(Periodic Maintenance) intervals are depend on hour meter records of operation. PM interval A : 8~10 hours or daily B : 50~250 hours or every month (Typical PM interval) C : 450~500 hours or every 3 months D : 900~1000 hours or every 6 months E : 2000 hours or every year Daily maintenance checks...
- Page 113 7. PERIODIC MAINTENANCE CHECKS 7. PERIODIC MAINTENANCE CHECKS The PM intervals are depend on hour meter records of operation. PM interval A : 8~10 hours or daily B : 50~250 hours or every month (Typical PM interval) C : 450~500 hours or every 3 months D : 900~1000 hours or every 6 months E : 2000 hours or every year Periodic checks and planned maintenance (PM)
- Page 114 Carefully read and understand these instructions and the specific maintenance procedures before attempting to do any repair work. When in doubt of any maintenance procedure, please contact your local HYUNDAI dealer. Powered industrial trucks can become hazardous if maintenance is neglected. Therefore, suitable maintenance facilities, trained personnel and procedures shall be provided.
- Page 115 Parts, including tires are to be installed per the manufacturer's procedures. Always use genuine HYUNDAI or HYUNDAI-approved parts. When removing tires follow industry safety practices. Most importantly, deflate pneumatic tires completely prior to removal.
- Page 116 9. MAINTENANCE GUIDE 9. MAINTENANCE GUIDE 1) 1) SUPPLYING BRAKE FLUID SUPPLYING BRAKE FLUID A hydraulically operated brake is employed. Check the level of brake fluid in the reservoir tank. When the level is low, refill. Do not mix with different kinds of brake fluid.
- Page 117 4) 4) CHECKING OF HUB NUT TIGHTENING CHECKING OF HUB NUT TIGHTENING CONDITION CONDITION Make sure that the hub nut is firmly tightened. T ightening and checking should be made in a diagonal order to prevent unbalanced tightening. (See the figure.) 15BT9UOM0705 5) 5) GREASING UP...
- Page 118 7) 7) CHECK FOR THE OIL LEVEL OF THE HECK FOR THE OIL LEVEL OF THE DRIVING GEAR CASE DRIVING GEAR CASE Check for the oil level by taking out the plug provided front side of the gear case. Drain plug Mag plug 15BT9UOM0706 8) 8)
- Page 119 HYUNDAI chain lubricant is recommended. It is easily sprayed on and provides superior lubrication. Heavy motor oil may also be used as a lubricant and corrosion inhibitor.
- Page 120 10. VISUAL INSPECTION 10. VISUAL INSPECTION First, perform a visual inspection of the lift truck and its components. ·Walk around the truck and take note of any obvious damage and maintenance problems. Check for loose fasteners and fittings. ·Check to be sure all capacity, safety, and warning plates or decals are attached and legible. ※...
- Page 121 5) 5) FORKS FORKS Inspect the load forks for cracks, breaks, bending, and wear. The fork top surfaces should be level 10% of "A" is and even with each other. The height difference max. wear allowed between both fork tips refer to below table. Fork length Height difference Model...
- Page 122 6) 6) WHEELS AND TIRES WHEELS AND TIRES Check the condition of the drive and steering wheels and tires. Remove objects that are embedded in the tread. Inspect the tires for excessive wear and breaks or chunking out. chunking out. Check all wheel lug nuts or bolts to be sure none of them is loose or missing.
- Page 123 11. CHECKING THE HYDRAULIC FLUID 11. CHECKING THE HYDRAULIC FLUID Check the hydraulic sump tank fluid level. Correct fluid level is important for proper system operation. Low fluid level can cause pump damage. Hydraulic fluid expands as its temperature rises. Therefore, it is preferable to check the fluid level at operating temperature (after approximately 30 minutes of truck operation).
- Page 124 13. AIR CLEANING THE TRUCK 13. AIR CLEANING THE TRUCK Always maintain a lift truck in a clean condition. Do not allow dirt, dust, lint or other contaminants to accumulate on the truck. Keep the truck free from leaking oil and grease. Wipe up all oil spills. Keep the controls and floorboards clean, dry and safe.
- Page 125 14. ELECTRIC TRUCK BATTERY MAINTENANCE 14. ELECTRIC TRUCK BATTERY MAINTENANCE BATTERY BATTERY SERVICE SERVICE AREA AREA 15BT9UOM0715 Battery charging 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.
- Page 126 15. BATTERY HANDLING 15. 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 127 16. BATTERY CHARGING 16. 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 BATTERY CHARGER MONITOR maintaining watch . AC IN CHARGE LEVEL FLOAT EQUAL ERROR...
- Page 128 2) 2) INSTALLATION OF THE CHARGER 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 129 17. BATTERY REMOVAL FROM TRUCK 17. BATTERY REMOVAL FROM TRUCK 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. 15BT9UOM0707 Release the battery cover latch.
- Page 130 4-1) Open the side door. (SBR Type, Option) Side door open 15BT9OM87 Remove the battery stopper. 15BT9UOM0722 Put down the battery with fork lift or chain block by hang up hook at 4 links which located in right and left of the battery. 15BT9UOM0723 7-22...
- Page 131 18. BATTERY CLEANING AND CARE 18. BATTERY CLEANING AND CARE 1) 1) AVOID OVER-DISCHARGE 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.
- Page 132 . Refer to this manual at all times properly. properly. ※ If you have any questions or technical If you have any questions or technical problems, contact HYUNDAI dealer. problems, contact HYUNDAI dealer. * Structure & function of battery pack connector* 7-23-1...
- Page 133 2) 2) Lithium Ion Battery Safety Matters Lithium Ion Battery Safety Matters ※ Proper handling and inspection are required for safe use of lithium-ion batteries. Proper handling and inspection are required for safe use of lithium-ion batteries. ※ Follow the instrustions to avoid accident. The explanations are in threee steps as below. Follow the instrustions to avoid accident.
- Page 134 ③ Ensure that the actual battery type matches the specified battery in the forklift. If the unsuitable battery is used, it can cause poor performance or damage to the truck during operation. ④ The battery pack is shipped with a charge of 30% to 50%, so charge it fully before use. ⑤...
- Page 135 ② Check + and - thoroughly when connecting cables. Causes damage to electronic parts. If cables and plugs are open due to corrosion or heat, contact your HYUNDAI dealer to replace them. ③ Do not modify the plug or connector arbitrarily. It may cause heat and explosion.
- Page 136 20. LITHIUM ION BATTERY CHARGER (OPTION) 20. LITHIUM ION BATTERY CHARGER (OPTION) ※ Before connecting the battery charger to the Before connecting the battery charger to the power supply and the battery, carefully read the power supply and the battery, carefully read the instructions below.
- Page 137 ⑨ Always use special bipolar connectors (DIN 320 REMA). ⑩ DO NOT use additional cables to extend the existing electrical connections. ⑪ The charging appliance is maintenance-free, except for routine cleaning that must be performed regularly and periodically according to the type of work environment. Before starting to clean the appliance, disconnect the power supply cable from the mains and the connection cables to the battery.
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Page 138: New Machine Oil
21. NEW MACHINE OILS New machine uses following lubricants and oils. Description Specification Gear oil ATF-Dextron Ⅲ Hydraulic oil ISO VG46/VG68, Hyundai genuine long life hydraulic oil ★1 ISO VG15, Conventional hydraulic oil Brake oil Brake Fluid DOT 3 Grease NLGI No.2 ·ATF : Automatic Transmission Fluid... -
Page 139: Specifications
8. SPECIFICATIONS 8. SPECIFICATIONS 1. SPECIFICATION 1. SPECIFICATION 15BT9UOM0801 Model Unit 15BT-9U 18BT-9U 20BT-9U Capacity kg (lb) 1500 (3000) 1800 (3500) 2000 (4000) ← ← Load center mm (in) 500 (24") Weight kg (lb) 3143 (6929) 3427(7555) 3561 (7850) ←... -
Page 140: Specification For Major Components
TSA200-100-269 TSA170-210-063 Type Rated voltage Output 14.9 IP Grade 3) 3) BATTERY BATTERY Item Unit 15BT-9U 18/20BT-9 ← Rated voltage Rack Dimension (W×L×H) 983×553×650 983×638×650 Battery weight(STD) 1000 Connector (CE spec) SB 350 or SR350 (SBE 320) 4) 4) CHARGER... - Page 141 1320 Gear ratio 26.75 Weight without fluid kg/lb 31/ 68 ℓ/U.S·qt Oil quantity 0.35/0.37 8) 8) WHEELS WHEELS Item 15BT-9U 18BT-9U 20BT-9U Type (STD/OPT) SOLID/Non-marking Quantity (front/rear) ← Front-drive 18×7 - 8 200 / 50 -10 ← ← Rear-steering 15×4.5 - 8 9) 9) BRAKES &...
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Page 142: Tightening Torque
3. TIGHTENING TORQUE 3. TIGHTENING TORQUE Items Size kgf·m lbf·ft M 8 ×1.25 2.5 ± 0.5 18.1 ± 3.6 Hyd pump motor mounting bolt Electric system M 8 ×1.25 2.5 ± 0.5 18.1 ± 3.6 Traction motor mounting bolt M 8 ×1.25 2.5 ±...
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