Table of Contents
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1. GENERAL SAFETY RULES
1. Daily inspection ------------------------------------------------------------------------------------------------------------- 1-1
2. Do's and dont's ------------------------------------------------------------------------------------------------------------- 1-2
3. No riders ------------------------------------------------------------------------------------------------------------------------ 1-4
4. Pedestrians ------------------------------------------------------------------------------------------------------------------- 1-5
5. Operator protection ------------------------------------------------------------------------------------------------------- 1-6
6. Fork safety --------------------------------------------------------------------------------------------------------------------- 1-7
7. Pinch points ------------------------------------------------------------------------------------------------------------------ 1-8
8. Travel ------------------------------------------------------------------------------------------------------------------------------ 1-9
9. Surface and capacity ---------------------------------------------------------------------------------------------------- 1-10
10. Parking --------------------------------------------------------------------------------------------------------------------------- 1-11
11. Lifting, jacking and blocking ----------------------------------------------------------------------------------------- 1-12
12. Loading and unloading by crane -------------------------------------------------------------------------------- 1-17
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 --------------------------------------------------------------------------------------------- 2-4
6. Right-angle stacking ----------------------------------------------------------------------------------------------------- 2-4
7. Chain slack -------------------------------------------------------------------------------------------------------------------- 2-5
8. Pallets and skids ----------------------------------------------------------------------------------------------------------- 2-5
9. Caution for electrical lines -------------------------------------------------------------------------------------------- 2-6
1. General locations ---------------------------------------------------------------------------------------------------------- 3-1
2. Data/safety plates and decals ------------------------------------------------------------------------------------- 3-3
3. Instruments and controls --------------------------------------------------------------------------------------------- 3-7
4. Instruments panel --------------------------------------------------------------------------------------------------------- 3-9
5. Operating switches and levers ------------------------------------------------------------------------------------ 3-14
6. Battery connector --------------------------------------------------------------------------------------------------------- 3-20
7. Support and safety parts --------------------------------------------------------------------------------------------- 3-20
CONTENTS
CONTENTS
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Table of Contents
Related Manuals for Hyundai 10BOP-7
Summary of Contents for Hyundai 10BOP-7
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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 dont's ------------------------------------------------------------------------------------------------------------- 1-2 3. No riders ------------------------------------------------------------------------------------------------------------------------ 1-4 4. Pedestrians ------------------------------------------------------------------------------------------------------------------- 1-5 5. Operator protection ------------------------------------------------------------------------------------------------------- 1-6 6. Fork safety --------------------------------------------------------------------------------------------------------------------- 1-7 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 -------------------------------------------------------------------------------------------- 5-1 2.
- Page 3 17. Battery installation & removal from truck ------------------------------------------------------------------- 7-23 18. Battery cleaning and care ------------------------------------------------------------------------------------------- 7-25 19. New machine oil ----------------------------------------------------------------------------------------------------------- 7-27 20. Recommended lubricants ------------------------------------------------------------------------------------------- 7-27 8. SPECIFICATIONS 8. SPECIFICATIONS 1. Specification ----------------------------------------------------------------------------------------------------------------- 8-1 2. Specification for major components --------------------------------------------------------------------------- 8-3 3.
- Page 4 HYUNDAI lift trucks 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 5 HYUNDAI lift truck in a safe and correct manner. Your HYUNDAI lift truck has been designed and built to be as safe and efficient as today's technology can make it. As manufactured, for some models, it meets all the applicable mandatory requirements of ANSI B56.1-1988 Safety Standard for Powered Industrial Trucks.
- Page 6 ※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 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 lift truck's features, operation, or manuals.
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Page 8: Safety Labels
Door open 13BOP7OM101 Model name Caution battery handling 14 Name plate-battery Warning mast Load capacity chart 15 Belt Hyundai logo 10 Hanger 16 Fork down Hand caution 11 Hook 18 Warning lifting Circuit diagram 12 Multifunction lever 19 Label-UL "E"... - Page 9 Door open 13BOP7OM101A Model name Caution battery handling 14 Name plate-battery Warning mast Load capacity chart 15 Belt Hyundai logo 10 Hanger 16 Fork down Hand caution 11 Hook 18 Warning lifting Circuit diagram 12 Multifunction lever 19 Label-UL "E"...
- Page 10 2. DESCRIPTION 2. DESCRIPTION There are several specific warning labels on this machine please become familiarized with all warn- ing labels. Replace any safety label that is damaged, or missing. 1) 1) WARNING MAST WARNING MAST (ltem 2) This warning label is positioned on the both top side of the mast.
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Page 11: Battery Handling
4) 4) BATTERY HANDLING BATTERY HANDLING (Item 8) This battery handling is located on the left middle side frame of the cab. ※ Refer to page 7-23 for a safe battery Refer to page 7-23 for a safe battery removal. removal. -
Page 12: Warning Safety
6) 6) WARNING SAFETY WARNING SAFETY (Item 13) This warning safety is located on the middle side frame of the cab. FOR SAFETY FOR SAFETY Before operating the truck, please check brakes, steering system, horns and other devices for safety and making it easy operation. - Page 13 GUIDE GUIDE 1. DIRECTION 1. DIRECTION The direction of this machine indicate forward, Left backward, right and left when machine is in the travelling direction. Forward Backward Right 10BOP7OM07 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...
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Page 14: General Safety Rules
1. GENERAL SAFETY RULES 1. GENERAL SAFETY RULES 1. DAILY INSPECTION 1. DAILY INSPECTION At the beginning of each shift, inspect your truck and fill out a check, maintenance and lubrication table. Check for damage and maintenance problems. Have repairs made before you operate the truck. -
Page 15: Do's And Dont's
2. 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. 13BOP7OM04 Don't smoke in NO SMOKING areas or when charging. D35AOM06... - Page 16 Don't operate the truck outdoors in rainy day. 13BOP7OM033 Don't perform battery charging service in the room without adequate ventilation. 13BOP7OM034...
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Page 17: No Riders
3. NO RIDERS 3. NO RIDERS The operator is the only one who should be on a truck. 13BOP7OM11 Never transport personnel on the forks of a lift truck. 13BOP7OM12... -
Page 18: Pedestrians
4. PEDESTRIANS 4. PEDESTRIANS Make sure that people stand back, even when you are parked. 13BOP7OM13 Watch for people in your work area even if your truck has warning lights or alarms. People may not watch for you. D35AOM14 Watch where you are going. Look in the direction of travel. -
Page 19: Operator Protection
5. OPERATOR PROTECTION 5. OPERATOR PROTECTION Keep under the overhead guard. Always keep your body within the confines of the truck. 13BOP7OM16 Be specially careful when traveling and maneuvering in tight areas. 13BOP7OM05... -
Page 20: Fork Safety
6. FORK SAFETY 6. FORK SAFETY Never allow anyone to walk under raised forks. B207OM17 There is special equipment to raise people for overhead work. DO NOT USE LIFT TRUCKS. 13BOP7OM19... -
Page 21: Pinch Points
7. PINCH POINTS 7. PINCH POINTS Keep hands, feet and legs out of the Keep hands, feet and legs out of the mast. mast. B207OM20 Don't use the mast as a ladder. Don't use the mast as a ladder. 13BOP7OM21 Never try to repair the mast, carriage, Never try to repair the mast, carriage, chain, or attachment yourself. -
Page 22: Travel
8. TRAVEL 8. TRAVEL Travel with the load near the floor/ground to cradle the load whenever possible. Never lift or lower the load when the Never lift or lower the load when the truck is in motion. truck is in motion. 13BOP7OM23 When handling bulky loads that restrict your vision always operate your truck in front... -
Page 23: Surface And Capacity
9. SURFACE AND CAPACITY 9. 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. Know the weight of your truck and load. Especially when using elevators, Know Especially when using elevators, Know the capacity of the elevator you intend to... -
Page 24: Parking
10. PARKING 10. PARKING Never park on a grade. 13BOP7OM33 Always come to a complete stop before leaving truck. Be sure travel control is in NEUTRAL. 13BOP7OM34 Lower forks fully to floor. 13BOP7OM35 Turn key to OFF position. 10BOP7OM36 1-11... -
Page 25: Lifting, Jacking And Blocking
11. LIFTING, JACKING AND BLOCKING 11. LIFTING, JACKING AND BLOCKING Lifting or jacking any large piece of equipment such as truck presents obvious hazards, it Lifting or jacking any large piece of equipment such as truck presents obvious hazards, it must be done with great care and forethought. - Page 26 Slowly lift truck and lower drive wheels onto the cradles or place blocking under frame prop points. When maintenance work is completed, lower the truck to the floor by reversing the lifting procedure. Check to be sure no tools or equipment are under the truck or wheels.
- Page 27 Hold the shorter block against the outer rail and lower the mast until inner rail rests on the block. Platform Reverse the procedure to remove Outer blocking. mast Middle mast Inner Rail mast block 10BOP7JB07 RAISING REAR OF TRUCK The truck may be raised at the front by lifting and blocking under the center of the frame member at the front frame.
- Page 28 Before performing any maintenance work, check the truck for stable condition on the blocking. RAISING ENTIRE TRUCK (Refer to page 1-19) Refer to truck data plate for truck weights. Park truck safely as described in "Safe Parking". Lower mast fully. If necessary, drive truck onto boards to increase ground clearance.
- Page 29 7) 7) SHIPPING TIE-DOWN INSTRUCTIONS SHIPPING TIE-DOWN INSTRUCTIONS (1) (1) Rear of truck Rear of truck ① With mast and platform installed a. Lower the platform fully. b. Put a tie down (e.g., chain) for each outside of the platform. ②...
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Page 30: Loading And Unloading By Crane
12. LOADING AND UNLOADING BY CRANE Check the specification of when you are going to hoist the truck. Before loading the truck, battery must be removed. Refer to page 7-23 for a safe battery removal. 14BRJ7OM136 Use long wire rope and stay to keep the distance with the machine as it should avoid touching with Stay Stay... - Page 31 Do not install the wire to unsafe position such as forks, platform, head guard, counterweight lifting hole or towing pin, Head guard (X) etc.. It can cause a serious damage to driver and truck. If there is any problem to lift a truck, please contact your dealer.
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Page 32: Operating Hazards
2. OPERATING HAZARDS 2. OPERATING HAZARDS 1. LOOSE LOADS 1. LOOSE LOADS Loose or unbalanced loads are dangerous. Loose or unbalanced loads are dangerous. Observe these precautions. Observe these precautions. Never carry loose or uneven material. 13BOP7OM39 Center wide loads. n t e i d e l o a... -
Page 33: Long And Wide Loads
2. LONG AND WIDE LOADS 2. LONG AND WIDE LOADS With long or wide loads, you need more With long or wide loads, you need more room. So slow down and watch your room. So slow down and watch your clearance. -
Page 34: Low Overhead Clearance
4. LOW OVERHEAD CLEARANCE 4. LOW OVERHEAD CLEARANCE Know the height of your truck, with and Know the height of your truck, with and without a load. Check your clearances. without a load. Check your clearances. Keep the load low. Keep the load low. -
Page 35: Fast Turns And High Loads
5. FAST TURNS AND HIGH LOADS 5. FAST TURNS AND HIGH LOADS Slow down before turning. Slow down before turning. The truck can tip over. The truck can tip over. Driver must always observe an adequate Driver must always observe an adequate braking distance. -
Page 36: Chain Slack
7. CHAIN SLACK 7. CHAIN SLACK Slack chains mean rail or platform Slack chains mean rail or platform hangup. hangup. Raise the forks before you move, or Raise the forks before you move, or broken chains can result. broken chains can result. D35AOM51 D35AOM52 8. -
Page 37: Caution For Electrical Lines
9. CAUTION FOR ELECTRICAL LINES 9. CAUTION FOR ELECTRICAL LINES When moving the machine with the mast When moving the machine with the mast raised, watch out electrical lines over the raised, watch out electrical lines over the machine. machine. The operation near the electrical lines is The operation near the electrical lines is very dangerous. -
Page 38: Know Your Truck
3. KNOW YOUR TRUCK 1. GENERAL LOCATIONS OUTLINE Platform 13BOP7OM51 Mast Steering wheel Fork Overhead guard Load tire Guide roller Drive unit and tire Platform... - Page 39 Additional lift 13BOP7OM51A Mast Steering wheel Fork Overhead guard Load tire Guide roller Drive unit and tire Additional lift...
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Page 40: 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 41 Battery handling decal Open the battery cover when charging. Battery being charged not only heat, but also inflammable hydrogen gas is produced. Keep fire away. Hoisting the battery case, use 4 wires with hook and handle carefully, not to shock. The electrolyte solution of battery is dilute sulfuric acid Be careful not to drop on clothes and mechanical parts.
- Page 42 Belt fastening decal The belt fastening decal is placed on the both side of the overhead guard. When operating the truck, bear in mind that operator should securely fasten the safety belt so that he can avoid from falling down to the ground. Do not operate truck unless the safety belt is securely fastened around you.
- Page 43 OPERATING SAFETY WARNING For safety Before operating the truck, please check brakes, steering system, horns and other FOR SAFETY devices for safety and making it easy operation. Only trained and qualified persons should operate this truck. Please operate the truck on suitable position in operator's platform.
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Page 44: Instruments And Controls
3. INSTRUMENTS AND CONTROLS PLATFORM 7 8 6 13BOP7OM61 Display Beacon lamp Key switch 10 Emergency switch Multifunction lever 11 Dead man switch Head lamp 12 Pallet clamp Fan switch 13 Pallet clamp pedal Work lamp switch 14 Pallet release pedal Beacon switch 15 Safety bar The multifunction lever, steering wheel, display, lamps and all switches, (key, emergency... - Page 45 ADDITIONAL LIFT 7 8 6 13BOP7OM61A Display Beacon lamp Key switch 10 Emergency switch Multifunction lever 11 Dead man switch Head lamp 12 Additional lift Fan switch 13 Safety bar Work lamp switch 14 Additional lift enable button Beacon switch 15 Additional lift lever The multifunction lever, steering wheel, display, lamps and all switches, (key, emergency stop, light etc) are located on the console.
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Page 46: Instruments Panel
4. INSTRUMENT PANEL STRUCTURE The instrument panel has six built-in red LCD, which provide the operator with an easy information about the status of some truck devices. 10BOP7OM65 Wrench warning lamp Key 5 button Thermometer warning lamp Key 6 button Dead man warning lamp 10 LCD Key 1 button... -
Page 47: Warning Lamp
WARNING LAMP When the key switch is OFF, the display makes a general test lighting and switching OFF all the LED in sequence. Wrench warning lamp This LED blinks when truck is in alarm condition. 16B7OM62 Thermometer warning lamp This LED blinks when one truck's controller is in alarm due IMS high temperature. -
Page 48: Tester Menu
TESTER MENU Status of keyboard buttons can be monitored in real time in the TESTER menu. Key 1 button Status of keyboard button: ON = Input active, button pushed OFF = Input not active, button released 16B7OM67 Key 2 button Status of TURTLE keyboard button: ON = Input active, button pushed... -
Page 49: Lcd Function
LCD FUNCTION 15B7OM77 Battery's state of charge The battery's state of charge indication is displayed on the left side of the unit (1); it is shown by ten notches. Each notch represents the 10% of the battery charge. As the battery becomes discharged, the notches turn off progressively, one after the other, in proportion to the value of the residual battery charge. - Page 50 Turtle The turtle symbol (3) is normally off; when it appears (fixed) it shows activation of the cutback mode and the "soft" mode of the truck, in which maximum speed and acceleration are reduced. The cutback mode is activated by the switch to severe height and steering angle, so it can be activated automatically as your operation and the "soft"...
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Page 51: Operating Switches And Levers
5. OPERATING SWITCHES, LEVERS AND PEDALS 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 is turned off. ON : Both control circuits for hydraulics and running can be activated. -
Page 52: Dead Man Switch
DEAD MAN SWITCH The dead man switch always keeps the operator's foot in place during driving the machine or hydraulic operation. If the dead man switch is not pressed, all the electrical functions are taken out of operation with exception of the steering, the display and the horn. - Page 53 ADDITIONAL LIFT ENABLE SWITCH (Option) As the auto return type switch, when pressing this switch, additional lift is enable. This switch always keeps the operator's left hand in place during opreating additional lift for safety. 13BOP7OM80 ADDITIONAL LIFT LEVER (Option) Pushing the lever upward the additional lift fork is moving up.
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Page 54: Multifunction Lever
MULTIFUNCTION LEVER The multifunction lever is located on the right side of the console. The multifunction lever allows on-handed operation for the following functions : Driving direction and speed for forward and backward. Lifting and lowering for the fork along with platform. Horn sounding. -
Page 55: Steering Wheel
Lifting and lowering Lifting work Turn the lift grip of the multifunction lever to clockwise for lifting the forks. Lift grip 10BOP7ML04 Lowering work Turn the lift grip of the multifunction lever to counterclockwise for lowering the forks. Lift grip 10BOP7ML05 Horn sounding The horn sounds when the horn switch is... - Page 56 PALLET PEDAL The pallet pedal is mounted on the platform Pallet release pedal weld assy to hold pulling power of the ratchet cable. Step down the pallet pedal in order to pucker Pallet pedal up the pallet clamps. Pallet clamp The release pedal is mounted on the platform weld assy to release pulling power of the ratchet cable.
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Page 57: Battery Connector
6. BATTERY CONNECTOR Be sure to connect the connector for the PUMP INVERTER battery and body. Battery cable connector TRACTION INVERTER LINE CONTACTOR 10BOP7OM87 7. SUPPORT AND SAFETY PARTS OVERHEAD GUARD The overhead guard is of rugged construc- tion that serves to ensure the safety of the operator. -
Page 58: Daily Safety Inspection
Do not make repairs yourself unless you are trained in 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 Do not operate a truck if it is in need of repair. -
Page 59: Visual Checks
2. 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. -
Page 60: Functional Checks
3. 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 Before performing these checks, familiarize yourself with the operating procedures in Section 5. 5. Test warning devices, horn, lights, and other safety equipment and accessories. -
Page 61: Operating Procedures
5. OPERATING PROCEDURES 5. OPERATING PROCEDURES 1. BEFORE OPERATING THE TRUCK 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. -
Page 62: Starting The Truck
3. STARTING THE TRUCK 3. STARTING THE TRUCK Before you start the truck, make sure that you have taken all the above mentioned precautions and the machine is in NEUTRAL. 1) 1) DRIVING DRIVING To start the truck, step down on and press the dead man switch. Insert the start key and turn it clockwise to the "ON"... -
Page 63: Stopping And Parking
3) 3) STOPPING AND PARKING STOPPING AND PARKING When parking the vehicle, step down on and press the dead man switch to lower the fork to the lowest position. Even if you only intend to leave the Even if you only intend to leave the truck for a short time, the truck should truck for a short time, the truck should be securely parked for safety. -
Page 64: Controlling Speed
4. CONTROLLING SPEED 4. CONTROLLING SPEED Turn the multifunction lever to clockwise for forward driving or counterclockwise for reverse driving. Turn to the multifunction lever smoothly it until the truck is moving at the desired speed. 5. BRAKING 5. BRAKING To stop the truck, take off the foot on the dead man switch. -
Page 65: Operating Safely
7. OPERATING SAFELY 7. OPERATING SAFELY Safe operation is the responsibility of the operator. 1) 1) Watch where you are going. Don’t go if you can’t see... 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 66 Travel with raised platform to fully clear the ground or obstacles. When the fork together with platform (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... Grades, ramps, and inclines...
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Page 67: Load Handling
8. LOAD HANDLING 8. LOAD HANDLING 1) 1) GENERAL 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 68 3) 3) LOAD ON FORKS LOAD ON FORKS Do not elevate the load with one fork. Loading with one fork cause the tip over, serious injury or death of operator. The work can cause the height difference between both fork tips. 13BOP7OM141 Do not elevate the load with the ends of the forks.
- Page 69 4) 4) TRAVELING WITH LOAD TRAVELING WITH LOAD Travel with load or fork and platform as low as possible. Never travel with the load or fork and platform 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.
- Page 70 5) 5) PICKING UP AND MOVING LOADS 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 71 7) 7) STACKING STACKING (1) (1) To put a load on a stack To put a load on a stack ① Approach slowly and align the lift truck and load squarely with the stack. 10BOP7OM103 ② Raise the load as the lift truck nears the stack. 10BOP7OM104 ③...
- Page 72 (2) (2) To move a load from a stack 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. Move reverse until the forks are under the load.
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Page 73: Shut Down Procedure
9. SHUT DOWN PROCEDURE 9. SHUT DOWN PROCEDURE ※ Always leave your lift truck in a safe condition. 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. -
Page 74: Emergency Precautions
6. EMERGENCY PROCEDURES 6. EMERGENCY PROCEDURES 1. EMERGENCY PRECAUTIONS 1. EMERGENCY 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. ※... - Page 75 2. MAST EMERGENCY LOWERING 2. MAST EMERGENCY LOWERING In case that the mast cannot be lowered due to a problem in the controller, activate the emergency lowering valve on the Manifold Emergency lowering valve manifold assy by pulling the steel lever. Platfrom Turn off the electric emergency switch.
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Page 76: 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 have need for more information on the care and repair of your truck, see you HYUNDAI dealer. -
Page 77: 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 78: Major Component Locations
5. MAJOR COMPONENT LOCATIONS 5. MAJOR COMPONENT LOCATIONS Use the illustration below to locate components included in the PM procedures. 1) 1) PLATFORM PLATFORM 13BOP7OM112 Mast EPS motor 15 Pallet clamp pedal Lift cylinder Traction motor 16 Safety belt Platform 10 Drive wheel 17 Safety lever Forks... - Page 79 2) 2) ADDITIONAL LIFT ADDITIONAL LIFT 13BOP7OM112A Mast Frame 13 Pump motor Lift cylinder EPS motor 14 Guide roller Additional lift Traction motor 16 Safety belt Forks 10 Drive wheel 17 Safety lever Drive unit 11 Load wheel 18 Free lift cylinder Dash board 12 Overhead guard...
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Page 80: Daily Maintenance Checks
6. DAILY MAINTENANCE CHECKS 6. DAILY MAINTENANCE CHECKS The PM intervals 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 81: Periodic Maintenance Checks
C : 450~500 hours or every 3 months D : 900~1000 hours or every 6 months E : 2000 hours or every year F : 5000 hours (Hyundai genuine long life hydraulic oil) Periodic checks and planned maintenance (PM) ●... -
Page 82: 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 83 Parts, including tires are to be installed per the manufacturer's procedures. Always use genuine HYUNDAI or HYUNDAI-approved parts. Use special care when removing heavy components, such as mast, etc.. Be sure that lifting and...
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Page 84: Maintenance Guide
9. MAINTENANCE GUIDE 9. MAINTENANCE GUIDE 1) 1) SUPPLYING HYDRAULIC OIL SUPPLYING HYDRAULIC OIL Lower the fork in its lowest position on an even ground. Check for the hydraulic oil level with the oil level gauge. When the level is low, refill. 10BOP7OM127 2) 2) CHECKING AND ADJUSTMENT OF... - Page 85 5) 5) CHECK FOR THE OIL LEVEL OF THE CHECK FOR THE OIL LEVEL OF THE DRIVING GEAR CASE DRIVING GEAR CASE Check for the oil level by taking out the filler plug provided front side of the gear Filler plug case.
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Page 86: Fuse Replacement
8) 8) FUSE REPLACEMENT FUSE REPLACEMENT PUMP INVERTER Disconnect the battery connector. Battery cable connector TRACTION INVERTER LINE CONTACTOR 10BOP7OM121 Remove the blown fuse and replace with a new one. SPARE SPARE SPARE 10BOP7OM120 ※ The blown fuse must be replaced with a fuse of the same capacity. When the fuses are The blown fuse must be replaced with a fuse of the same capacity. -
Page 87: Guide Roller
LOAD TIRE LOAD TIRE The load tires are mounted on the leg of Load tire the machine to enable it to drive smoothly. When operating the machine, make sure that the bearings are operated properly and the load tires are maintained good condition at any time. -
Page 88: 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 89: Visual Inspection
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 90 5) 5) FORKS FORKS Inspect the load forks for cracks, breaks, bending, and wear. The fork top surfaces should be level and even with each other. The height difference between both fork tips refer to below table. Fork length Height Model (mm) difference(mm)
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Page 91: Checking The Hydraulic Fluid
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 92: Air Cleaning The Truck
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 93: Electric Truck Battery Maintenance
14. ELECTRIC TRUCK BATTERY MAINTENANCE 14. ELECTRIC TRUCK BATTERY MAINTENANCE BATTERY SERVICE AREA B15AOM128 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 94: Battery Handling
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. Battery contains sulfuric acid (H ) which is toxic and corrosive solution. -
Page 95: Battery Charging
16. BATTERY CHARGING 16. BATTERY CHARGING The charger is of the automatic type so that only requirement for charging is to insert t h e p l u g , t h e r e b e i n g n o n e e d f o r maintaining watch. -
Page 96: Installation Of The Charger
⑧ Ordinary/Equalizing charge convert switch Ordinary/Equalizing charge convert switch : Place the switch to left side for ordinary charge and to right side for equalizing charge. ⑨ Manual stop button Manual stop button : During charge, push this button to stop charging. ⑩... - Page 97 4) 4) EQUALIZING CHARGE EQUALIZING CHARGE Continual repetition of ordinary charge will create a certain amount of performance difference among the cells. For this reason, the battery is slightly overcharged from time to time to equalize the performance among the cells, that is, given equalizing charge. Equalizing charge should be given in the following cases: ①...
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Page 98: Battery Installation & Removal From Truck
17. BATTERY INSTALLATION & REMOVAL FROM TRUCK 17. BATTERY INSTALLATION & 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: 1) 1) BATTERY REMOVAL BATTERY REMOVAL... - Page 99 2) 2) BATTERY INSTALLATION BATTERY INSTALLATION Using a battery hanger, carefully put the battery assembly compartment push the battery assembly to the frame. Adjust the lock screw of side support in frame. Connect the battery connector. Complete installation. 13BOP7OM122 ※ Make certain that the battery is securely Make certain that the battery is securely installed in the battery assembly...
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Page 100: Battery Cleaning And Care
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 101 3) 3) REFILLING DISTILLED WATER REFILLING DISTILLED WATER Refill distilled water to maintain the electrolyte level to the specified height after finishing equalizing charge, because electrolyte is lost through decomposition during charge and also through natural evaporation. It is unnecessary to refill dilute sulfuric acid into the battery except the case of losing electrolyte by running over.
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Page 102: New Machine Oil
New machine uses following lubricants and oils. Description Specification Gear oil SAE 80W-90 Hydraulic oil ISO VG46, Hyundai genuine long life hydraulic oil Grease NLGI No.2 ·API : American Petroleum Institute ·SAE : Society of Automotive Engineers ·ISO : International Organization for Standardization ·NLGI : National Lubricating Grease Institute... -
Page 103: Specifications
8. SPECIFICATIONS 8. SPECIFICATIONS 1. SPECIFICATION 1. SPECIFICATION 1) 1) PLATFORM PLATFORM 13BOP7SP01 Model Unit 10BOP-7 13BOP-7 Capacity 1000 1360 ← Load center Weight (with battery) 2866 3007 ← Max lifting height 3275 ← Min lifting height Fork ← Max spread width ←... - Page 104 2) 2) ADDITIONAL LIFT ADDITIONAL LIFT 13BOP7SP01A Model Unit 10BOP-7 13BOP-7 Capacity 1000 1360 ← Load center Weight (with battery) 3043 3184 ← Max lifting height 3275 ← Min lifting height ← Fork Additional lift ← Max spread width ←...
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Page 105: Specification For Major Components
Specification Type Fixed displacement gear pump Displacement cc/rev 19.6 Rated pressure Speed (max/min) 3000/500 4) 4) MANIFOLD ASSY MANIFOLD ASSY Specification Item Unit 10BOP-7 13BOP-7 Standard Option Standard Option ← ← ← Rated flow ← ← ← Maximum pressure ←... - Page 106 BRAKES Item Unit Specification Type Electromagnetic brake 8) 8) BATTERY BATTERY Dimensions Voltage Capacity Weight Model Length (L) Width (W) Height (H) 38.3 14.4 31.1 600±30 10BOP-7 38.3 14.4 31.1 725±35 38.3 16.3 31.1 730±35 13BOP-7 38.3 16.3 31.1 830±40...
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Page 107: Tightening Torque
3. TIGHTENING TORQUE 3. TIGHTENING TORQUE 1) 1) 10/13BOP-7 10/13BOP-7 Items Size kgf·m lbf·ft Hyd pump motor mounting bolt M10×1.5 Electric system Traction motor mounting bolt M 8×1.25 4.1±0.4 29.7±2.9 Hydraulic pump mounting bolt M10×1.5 36.2 Hydraulic MCV mounting bolt, nut M10×1.5 6.9±1.4 50±10...
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