Hyundai 25B-7A Operator's Manual
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Hyundai 25B-7A Operator's Manual

Hyundai 25B-7A Operator's Manual

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25/30/35B-7A
OPERATOR'S MANUAL

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Summary of Contents for Hyundai 25B-7A

  • Page 1 25/30/35B-7A OPERATOR’S MANUAL...

  • Page 2: Table Of Contents

    Table of Contents Table of Contents ........................................1 Brief Introduction ........................................2 I Safety ..............................................3 1. Applications of Forklift Truck ...................................3 2. Operating Sites and Working Environments of Forklift Truck .......................3 3. Safety Issues before Use ....................................5 4. Safety Issues before Use and during Operation ..........................8 5.

  • Page 3: Brief Introduction

    Brief Introduction This Manual shall be kept and repeatedly read by operators. · The items of this Operating Manual include Correct Selection, Simple Maintenance, and Routine Examinations. · Please read this Manual carefully, prior to operation, for proper driving and maintenance to ensure safety and effective material conveyance.

  • Page 4: I Safety

    I Safety Safety is your undertaking and liability. This chapter has mainly introduced the basic safety rules and warnings during normal use of the typical forklift truck. However these are applicable to the vehicles of special specifications with masts and attachments 1.
  • Page 5 △ ! Warning · The driving force of forklift truck may be increased, after anti-skid chain is fitted, but the side skidding performance is reduced, for which special attention shall be aroused. (2) Climatic Conditions △ ! Warning · Under the situation when wind power is very strong, try as much as possible to avoid high lifting actions of mast, to avoid drop of cargo, which may cause accident injury to driver.

  • Page 6: Safety Issues Before Use

    In torrid season or under torrid environment, please supply distilled water or deionized water readily, as the moisture is liable top evaporate in torrid season, while it is not allowed to add other liquids, including purified water. It shall be examined once a week that the supply of distilled water enables the height for liquid level of electrolyte to be in the specified range.
  • Page 7 · Please put on work clothes, labor protective shoes, and wear safety helmet when truck is driven. · Please don’t wear loose clothes, for the sake of safety, to avoid being caught up on leading to unexpected danger. (3) Driving Forklift Truck after Alcoholic Drinks Strictly Prohibited △...
  • Page 8 · Without the approval in writing of our Company, it is not allowed to refit or add any operating devices to forklift truck, and otherwise it may possibly affect the rated load or safe operation. · Avoid installing any parts that may block off the driver’s sight line. (7) Regular Maintenance △...

  • Page 9: Safety Issues Before Use And During Operation

    4. Safety Issues before Use and during Operation (1) Notices during Initial Startup △ ! Attention · Pull up hand brake. · Adjust seat, to facilitate hand/foot control. · Ensure that there is no person on, under, in front of, or behind the forklift truck.
  • Page 10 · Decelerate running speed and hoot, when passing other forklift trucks. · Avoid running into soft ground. · Please decelerate running speed, when running on damp, slippery, unsmooth, or inclined pavements. · Ensure that there is certain clearance between mast and roof as well as access door. (4) Driving during Rise of Fork Prohibited △...
  • Page 11 (6) Push/Pull Operation Prohibited △ ! Attention · It is not allowed to push/pull cargo using forklift truck, and otherwise cargo may possibly be damaged or fall off. (7) Driving on Ramp △ ! Attention · Following rules shall be observed when forklift truck is driven on a ramp.
  • Page 12 (9) Anyone on/under Forklift Truck Prohibited △ ! Warning · It is strictly prohibited to carry anyone on fork or pallet. · It is not allowed for anyone to take the forklift truck except driver. · Avoid using anyone to replace counter weight. ·...
  • Page 13 (12) Into-Carriage Operation △ ! Attention · Loading-unloading operation can only be performed on cargo deck with trailer properly fixed for forklift truck. · Fix bridge piece properly and examine its strength, prior to start of operation. · Decelerate the truck during access into the carriage, and pay attention to the safety of bridge piece.
  • Page 14  Notes · When chain is loose, pull a little bit the lifting handle upward, for fork to rise, so as to correct the loose status of chain. · When value of change in chain pitch exceeds the standard value by 2%, the chain must be replaced, to ensure the load-bearing safety.
  • Page 15 · If forklift truck is parked at roadside, caution or “Failure” shall be marked on the truck, and the key shall be pulled off. · If fork cannot be dropped for failure, a rather obvious mark shall be made in this place, to prevent bumping into other vehicles and pedestrians.

  • Page 16: Safety Issues During Service And Maintenance

    5. Safety Issues during Service and Maintenance (1) Sites for Maintenance and Service △ ! Attention · They shall be the designated sites and able to provide the service office with enough equipment and safety protective facilities. · This site shall be a level ground. ·...

  • Page 17: Safety Issues For Use Of Battery

    (5) Use of Jack (during Tire Replacement) △ ! Warning · It is not allowed for human body to get into under the forklift truck, when jack is used to jack up the truck. △ ! Attention · It shall be ensured that there is no body and no load either on the forklift truck, when jack is used to jack up the truck.
  • Page 18 (6) Keeping Clean △ ! Attention · Keeping Clean the Surface of Battery · Don’t use dry cloth, and chemical fiber fabric to clean the surface of battery, and don’t use polyethylene film to cover the battery, as such operation may possibly generate static electricity which may initiate accident. ·...

  • Page 19: Safety Issues For Installation, Adjustment, And Use Of Attachments

    △ ! Attention Please contact the Sales Department of our Company, when following situations occur with battery: · Battery smells. · Electrolyte turns to be turbid. · Temperature of electrolyte turns to be high. · Reducing speed of electrolyte is too fast. (13) Disassembly Prohibited △...
  • Page 20 a fairly detailed understanding about the allowable loads and lifting heights of the attachments as well as the dimensions of cargo and the applicable scopes of attachments. b) When attachments of forklift truck with multiple functions are operated, it shall not allow the two actions to be performed at the same time, and the other action must proceed only after one action has been completed.

  • Page 21: Label Plates

    8. Label Plates Label plates pasted on truck are used to indicate operating methods and notices of truck. This is not only the consideration for you, but also the consideration for the truck. Please re-paste the label plate immediately, after any of them is dropped out.
  • Page 22 (4) Label Plate for Lubricating System Drawing (5) Label Plate for Load Curve Diagram(Demonstration) △ ! Attention...
  • Page 23 (6) Label Plate for Operating Notices △ ! Attention (7) Label Plate for Maintenance Notices △ ! Attention...
  • Page 24 (8) Label Plate for Adding Hydraulic Oil  Note: (9) Label Plate for Tire Safety (Pneumatic Tire) △ ! Warning (10) Label Plate for Lifting △ ! Attention...
  • Page 25 (11) Label Plate for Prohibition from Entering Rear Space of Mast △ ! Warning (12) Data Plate for Tire Air Pressure (Pneumatic tire) (Demonstration) (13) Label Plate for Attention to Hand Injury △ ! Warning...

  • Page 26: Operating Devices And Operating Methods

    Operating Devices and Operating Methods 1. Outside Mast 7. Fork 13. Overhead Guard 2. Inside Mast 8. Front Wheel 14. Counterbalance Weight 3. Lifting Cylinder 9. Tilting Cylinder 15. Seat 4. Lifting Chain 10. Rear Wheel 16. Front Combination Light 5.
  • Page 27 1. Brake Liquid Lid 7. Emergency Parking Switch 13. Lifting Handle 2. Left Instrument Panel 8. Instruments 14. Accelerator 3. Hand Brake 9. Right Instrument Cover 15. Key Switch 4. Direction Switch 10. Attachment Handle 16. Brake Pedal 5. Horn Pushbutton 11.

  • Page 28: Lcd (Liquid Crystal Display) Instruments

    1. LCD (Liquid Crystal Display) Instruments Instruments ⓐ: Operating Modes: Pressing ⓖ is able to change operating mode, “N” as the standard mode, “F” as the fast mode, and “S” as the slow mode. ⓑ: Forward Indication ⓒ: Backward Indication ⓓ: Traction Failure Indication Area –...
  • Page 29 Instrument The SMARTDISPLAY display is a kind of smart instrument panel connected on the truck system through CAN bus. This SMART instrument provides diagnosis and setup for the CBU system. Diagnosis and setup include the SMARTDISPLAY itself, traction controller, lifting controller, and valve controller. The SMART display menu enters into the SMART instrument menu through six operating pushbuttons fixed on touch keyboard.

  • Page 30: Switches Part

    2. Switches Part (1) Light Switch Light switch is a rotational 2-gear switch. Power Supply Width Indicator Far Beam 1st Gear 2nd Gear X indicates switched-on. △ ! Attention On/Off of this light is irrelevant with the position of key switch, and so pay attention not to forget turning off the light.
  • Page 31 △ ! Warning As full hydraulic steering is applied to the forklift truck, the steering will be very difficult, when steering motor has stopped running. The steering motor must be started immediately, for steering for a second time. (2) Lifting Control Rod Pushing/pulling this handle forward or backward for the fork to be able to fall and rise.
  • Page 32 During parking brake, this handle acts on the front wheel through back tip, for brake to generate braking force. Push forward the handle to loosen the brake. Micro switch is available on the left side of hand brake, and pulling tight the handle may invalidate the operation. △...

  • Page 33: Truck Body Part

    △ ! Attention Never push down the accelerator pedal and the brake pedal simultaneously, and otherwise the running motor will be damaged. 4. Truck Body Part (1) Seat and Seat Adjusting Lever Move the seat adjusting lever rightwards, to adjust seat to a position comfortable for sitting and easy for operation.
  • Page 34 Brake oil cup is located on the left side of front wall inner shield. △ ! Attention Prevent dust and mixed cargo from entry into the oil cup, when brake fluid is filled. Brake fluid is corrosive and toxic. (8) Front Headlight and Front Combination Light Two front headlights and front combination light (turn signal light and width light) are installed on the front support of overhead guard.

  • Page 35: Driving And Operation

    Driving and Operation Some notices for correct driving operation are introduced here, in order for your truck to maintain good performance, safe use, and frequent operation. 1. Use of New Truck The service life of your truck depends on use at the time when the truck is new. In the early stage of 200-h operation, please pay high attention to the following items: △...

  • Page 36: Stability Of Forklift Truck

    4. Stability of Forklift Truck The standard for stability of forklift truck is specified in ISO or other standards. However the stabilities described in these standards are not applicable to all the operating status, while the stabilities of forklift truck vary for different operating status.

  • Page 37: Running

    (1) Before Starting Forklift Truck · Prior to truck operation, it shall be examined as to whether or not all the control devices and warning devices are under normal operation, and it is prohibited to start forklift truck, if there is any damage or failure which has not yet been corrected.
  • Page 38 Slowly push down the accelerator pedal for truck to start running. Sudden commutation is prohibited during forward/backward operation. △ ! Warning The truck must be decelerated · At crossroads · In crowded places · On rough grounds and other rugged surfaces ·...

  • Page 39: Loading

    hindering the operation of other vehicle and personnel. 8. Loading (1) The spacing of fork shall be as large as possible, for a good traverse stability. (2) The forklift truck and the cargo shall be aligned, when for inserts into pallet or directly into cargo. (3) The fork must be inserted in parallel, relative to the pallet.

  • Page 40: Unpiling

    (8) Observe the space behind the forklift truck, and run the truck backward to avoid bump of fork and pallet into each other. (9) Make sure that the front part of fork has left the Cargo or pallet, and lower the fork to facilitate running. 10.

  • Page 41: Storage

    11. Storage (1) Before Storage The forklift truck shall be thoroughly cleaned, and examined according to the following procedure, before it is stored: a) Clean and remove the oil and grease attached on the truck body using cloth and clear water, as per requirement.

  • Page 42: Regular Examination And Maintenance

    IV Regular Examination and Maintenance A comprehensive examination of the forklift truck in advance may avoid truck failure generation and inability to reach its due service life. The number of hours listed in the Regular Maintenance Timetable is determined, based on 8-hour work a day and 200-hour work a month for the forklift truck.
  • Page 43 Examine the status of tires. Too low air pressure may reduce the service life of tire, and increase electricity consumption. Different air pressures for left and right tires or damage of tire may cause different steering forces. The data plate pasted on the side of the hood of electric forklift truck has indicated the tire standard air pressures. Truck Tonnage Tire 2.5t-3t...
  • Page 44 (4) Examination of Overhead Guard The overhead guard plays a protective function, and it shall be ensured that it is firmly mounted and all the structural components are firm. (5) Examination of Brake Fluid Level Vent hole Examine the level of brake fluid reservoir, and the fluid level shall be between the two cases. It shall be avoided for dust or water to enter into fluid reservoir, during addition.
  • Page 45 Examine the hydraulic oil level using oil leveler, pull out the oil leveler and wipe it up. Re-insert it and then pull it out, to see whether or not the oil level is located between the high and low two scale lines. △...
  • Page 46 It shall be confirmed that the parking brake is safe and reliable, after the parking brake operating handle is pulled Preparation prior to start, Before turning on the power supply, ensure that the gear-shift handle is located at neutral gear, and parking brake is reliable.

  • Page 47: Maintenance

    Examine the rotation as well as the axial loosening status of steering wheel. The normal free stroke is 50-100mm, and axial loosening is not allowed. (25) Examination of Brake Drive the truck at a slow speed and push down the brake pedal to examine the braking effect. The brake light turns on, after the brake pedal is pushed down.
  • Page 48 · Continue jacking up the truck until the tire is off ground, take off the nuts and remove the tire. · The installation of tire is contrary to the disassembly sequence, and the wheel hub nuts shall be tightened up in a diagonal order.

  • Page 49: Regular Maintenance Timetable

    4. Regular Maintenance Timetable This timetable is set based on the standard working time and operating conditions, and please perform the maintenance beforehand, if the forklift truck is working under atrocious conditions (“●” indicating replacement). Power Transmission Wheel Daily Monthly Quarterly Semiannually Annually...
  • Page 50 Steering System Daily Monthly Quarterly Semiannually Annually Item Examination Items Tool (8 Hours) (200 Hours) (600 Hours) (1200 Hours) (2400 Hours) Clearance to be ○ ○ ○ ○ ○ Examined Axial Loosening to ○ ○ ○ ○ ○ Steering be Examined Wheel Radial Loosening ○...
  • Page 51 Brake System Daily Monthly Quarterly Semiannually Annually Item Examination Item Tool (8 Hours) (200 Hours) (600 Hours) (1200 Hours) (2400 Hours) ○ ○ ○ ○ ○ Idle Stroke ○ ○ ○ ○ ○ Pedal Stroke Diving Ruler ○ ○ ○ ○...
  • Page 52 Master Cylinder and Wheel Cylinder ● Leakage and Damage Status Whether or not Mounting Parts of Detection ○ ○ ○ ○ Brake Drum are Hammer Loosened Wearing Status of Vernier ○ Friction Plate Calipers Status of Brake ○ Shoe Action Whether or not ○...
  • Page 53 Lifting System Daily Monthly Quarterly Semiannually Annually Item Examination Item Tool (8 Hours) (200 Hours) (600 Hours) (1200 Hours) (2400 Hours) Damage, Distortion, and ○ ○ ○ ○ ○ Wear Status of Fork Damage and Wear Status ○ ○ ○ of Positioning Pin Fork Crack and Wear Status of...
  • Page 54 Crack and Damage ○ ○ ○ ○ Status of Roller and Roller Shaft Tensioning Status, Whether or not ○ ○ ○ ○ ○ Distorted, Damaged, or Rusted of Chain to be Examined ○ ○ ○ ○ Oil to be Added for Chain Chain and Riveted Pin and ○...
  • Page 55 Lifting System Daily Monthly Quarterly Semiannually Annually Item Examination Item Tool (8 Hours) (200 Hours) (600 Hours) (1200 Hours) (2400 Hours) Whether or not ○ ○ ○ ○ Status is Normal to Attachments be Examined Whether or not Piston Rod, Piston Rod Thread, and Detection ○...
  • Page 56 Hydraulic System Daily Monthly Quarterly Semiannually Annually Item Examination Item Tool (8 Hours) (200 Hours) (600 Hours) (1200 Hours) (2400 Hours) Oil Quantity to be ○ ○ ○ ○ ○ Examined, or Oil to be Replaced Suction Oil Filter Hydraulic ○...
  • Page 57 Electrical Daily Monthly Quarterly Semiannually Annually Item Examination Item Tool (8 Hours) (200 Hours) (600 Hours) (1200 Hours) (2400 Hours) Light as well Whether or not as Message ○ Lighting and ○ ○ ○ ○ and Sound Hooting are Normal Devices Battery Densimeter,...
  • Page 58 Safety Devices and Accessories Daily Monthly Quarterly Semiannually Annually Item Examination Item Tool (8 Hours) (200 Hours) (600 Hours) (1200 Hours) (2400 Hours) Whether or not Bolts are Damaged ○ ○ Seat or Loosened to be Examined Whether or not Truck Frame and ○...
  • Page 59 △ ! Attention · When oil different from that specified for this truck, its replacement cycle cannot be the same as that specified in this Manual. On this account, the time for replacement shall be shortened by 1/2 or 1/4 compared with the time specified in this Manual.

  • Page 60: Miscellaneous

    Miscellaneous Drawing of Lubricating System Lubrication System Diagram Mast Lift Chain Support Mast Tilting Differential Cylinder Pin Brake Fluid Wheel Bearing Operating Oil Tank Steering Wheel Bearing Con-rod Steering Knuckle Pin Inspection Every 8H Inspection Every 10H Inspection Every 30H Inspection Every 60H Inspection Every 120H...

  • Page 61: Oils Used For Forklift Truck

    Oils Used for Forklift Truck Name Capacity(L) Specification Gear Oil GL-5 85W/90 Hydraulic Oil 30(2.5T)/40(3, 3.5T) L-HM32 Brake Oil HZY3 (DOT 3) Lubricating As Need 2# Lithium Grease Grease △ ! Attention · Oil products of different brands cannot be blended in use. 3.
  • Page 62 LITHIUM-ION BATTERY INSTRUCTION Contents 1. Structure and Wiring Diagram-----------------------------------------------------------------------------------3 1.1 Product Specification--------------------------------------------------------------------------------------3 1.2 Product Sketch----------------------------------------------------------------------------------------------3 2. Safety Instruction---------------------------------------------------------------------------------------------------4 2.1 Inspection----------------------------------------------------------------------------------------------------4 2.2 Switching Machine-----------------------------------------------------------------------------------------4 2.3 Battery Discharging----------------------------------------------------------------------------------------5 2.4 Battery Charging--------------------------------------------------------------------------------------------5 3. Maintenance--------------------------------------------------------------------------------------------------------6 4. Malfunction and Deal---------------------------------------------------------------------------------------------7 5. Storage and Transportation---------------------------------------------------------------------------------------8 6. Warning and Tips--------------------------------------------------------------------------------------------------8...

  • Page 63: Structure And Wiring Diagram

    1. Structure and Wiring Diagram 1.1 Product specification Product Model Product Specification Application Counterbalance Forklift (2.5-3.5 ton) Lifepo4 Battery Pack Counterbalance Forklift supply 1.2 Product Sketch Products Drawing 2. SAFE OPERATION GUIDANCE 2.1 Inspection ·Before assemble，please check the battery volt and SOC (30%-90%) are in the normal value; ·Please check the positive and negative pole of the connector and storage system are matched.

  • Page 64: Maintenance

    2.3 Discharging When the storage system work, then the battery discharge. when the electric quantity lower than 10%,or the min volt of cell lower than 3.0V,the buzzer will alarm, then you need to charge the battery timely. overcharge or over-discharge will damage the battery. 2.4 Charging - 2.4.1 Before using the battery or forklift stop working, please charge the battery timely.

  • Page 65: Storage And Transportation

    and oil stain at the contact of the connector. * Step 2: Check whether the battery discharge outlet plug is firmly connected to the car body plug, you can try several times over. * Step 3: If the above two operation failures still exist, please contact our company for after-sales consultation. 5.

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