Hyundai 30EPER Operator's Manual
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Hyundai 30EPER Operator's Manual

Hyundai 30EPER Operator's Manual

Electric pallet truck
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30EPER
Electric Pallet Truck
 Operator's Manual
 Service Manual

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Summary of Contents for Hyundai 30EPER

  • Page 1 30EPER Electric Pallet Truck  Operator’s Manual  Service Manual...
  • Page 2 Welcome to choose “HYUNDAI” electric pallet truck! We hope our electric trucks will bring great convenience to your work!  Please read the manual carefully before operation.  This manual is a common manual. We reserve the right to modify technology of the electric pallet truck.

  • Page 3: Table Of Contents

    Content Brief introduction………………………………………·………………………….1 Ⅰ. Technical parameters …………………………··…………………………….2 Ⅱ. Structure description……………………………·…………………………….4 Ⅲ. Safety norms………………………………………………………………….7 Ⅳ. Drive and operation…………………………··…………………………….12 Ⅴ. Storage battery and charge……………………………………………….14 Ⅵ. Inspection before operation……………………………………………….17 Ⅶ. Inspection after operation……………………···………………………….18 Ⅷ. Periodic maintenance and repair………………………………………….18 Ⅸ. The store and transportation of forklift…………………………………25 Ⅹ.

  • Page 4: Brief Introduction

    Brief introduction： 30EPER series electric pallet truck is powered by storage battery, and driven by motor. This kind of truck travels by means of gear drive. The fork is lifted by means of DC motor and hydraulic transmission, which motivate hydraulic cylinder up and down to lift fork and goods together. As this truck is electrically driven for traveling and lifting, it possesses many characteristics, such as labor-saving, high efficiency, stability in operation, simple and easy operation, safety and reliability, little noise, environmental friendly, etc.

  • Page 5: Ⅰ. Technical Parameters

    I. Technical parameters : 1. 30EPER Outline drawing：...
  • Page 6 2. Main technical parameter HYUNDAI Manufacturer 30EPER Model Driving model：Electric(storage battery), diesel, gasoline, Electric(storage battery) fuel gas Driving model （ Manual, Walking, Stand driving, Seat Stand driving driving ,Order picking） Rated load Q(kg) 2500 Load center distance (mm) Front overhang...

  • Page 7: Ⅱ. Structure Description

    Ⅱ. Structure description： 1．Structure of the entire truck： 1 Power switch 2 Lifting button 3 Horn button 4 Accelerator knob 5 Operation handle 6 Emergency reverse button 7 Multi-functional instrument 8 Electric lock 9 Electric control unit 10 Driving unit 11 Platform 12 Steering power unit 13 Hydraulic power unit...
  • Page 8 2 Function introductions of instrument and operational control pieces: ⑴ Instrument : Battery capacity indicator； 2. Fault indicator； 3. Low-speed indicator； 4. Accumulative working time and fault code indicator This instrument is a combination of battery capacity indicator, LCD hour meter, fault code and low-speed indicator, with the battery capacity indicator of five segments of colorful LED display.
  • Page 9 travel in another direction. When the accelerator knob is released during truck traveling, regenerative braking will take effect, making the truck slow down to stop. Area C：When the operation handle is in area C, the truck will be in a state of traveling. When the accelerator knob is turned to one direction, the truck will travel in this direction.

  • Page 10: Ⅲ. Safety Norms

    another direction. Likewise, the truck will speed up with the increasing of rotation amplitude of the knob. Horn button： Horn of the truck will be turned on if you press the button. Emergency reverse button: when the operation handle is placed in area B and the emergency reverse button is pressed, the truck will travel in an opposite direction away from the operator immediately.
  • Page 11 It is strictly forbidden to make sharp turn on narrow aisle. When it is turning, slow down the truck so ⑽ as to ensure the safety of personnel and goods. Descend the forks to the lowest position when the truck is not used. ⑾...
  • Page 12 ⑸ Integrity of the truck shall be realized: Warning Do not make modifications on the truck. A Please observe safety rules and regulations of your working place during operation, inspection and maintenance of the truck. B No modification or addition shall be made to the truck without written permission by our company. A modification of the truck may have a negative effect on its safe operation.
  • Page 13 2 Safety Operation Specification： ⑴ Check the safety condition around the truck: Notice Before starting up the truck, please ensure that there is no person around it. Notice If the driver’s view is shielded by the bulky goods carried, please drive backwards or drive under the guidance of other working personnel.
  • Page 14 ⑵ Strictly forbid harsh driving： Notice Never start up, brake or turn abruptly. Abrupt start-up or braking may cause the falling of goods. Abrupt turning during traveling may cause the tilting of truck and result in serious accident. Do decelerate and take care to turn. Notice Observe all items of safety rules on working place.

  • Page 15: Ⅳ. Drive And Operation

    The faulty truck for future repair must not be parked at places impeditive for traffic. Lower down the fork arms to the lowest position and put on the warning board. Pull off the key. 4 Important notice after operation: 1）Parking: Park the truck at appointed place. Never park the truck on slope. Ensure the following points to be achieved before leaving away the truck: Lay down the fork to the lowest position naturally.
  • Page 16 2. Driving： ⑴ Start-up ： Warning When forking goods or moving goods, never rotate the accelerator knob rapidly to speed up the truck abruptly. Turn the switch of electric lock to ON position. When the operation handle is turned to area B or area C and accelerator knob is rotated slowly, the truck will start gradually.

  • Page 17: Ⅴ. Storage Battery And Charge

    ③ Adjust position of the truck, placing it in front of place where goods locate ； ④ Slowly start the truck, and insert fork arms to the bottom of goods as deeply as possible ； ⑤ Press the lifting button, raising forks to a position with a distance of over 40mm between bottom of the pallet and ground ；...
  • Page 18 1 Initial charge 1.1 Initial charge shall be made for new battery, i.e. The first time charge. Clean up the surface of the battery before the initial charge, and then check for damage to ensure reliable connection. 1.2 Open gas cap 1.3 When the charging equipment is able to operate normally, pour the sulfuric acid electrolyte with a density of 1.260±0.005 (25℃) and a temperature of lower than 30℃...
  • Page 19 2 Use and maintenance 2.1 In order to guarantee the service life of the batteries, the batteries in use should be fully charged. Insufficiently charged batteries must not be used. During the process of use, close attention should be paid to the discharge extent. Over discharge is prohibited---the voltage reduces to 1.7V per battery (when the total voltage reduces to 1.7V×12 = 20.4V).

  • Page 20: Ⅵ. Inspection Before Operation

    4 Operation of electrolyte ⑴ Density check The suction type densimeter shall be used to check density. During operation, avoid spilling out the electrolyte, and do wear protection appliance. ⑵ Operation besides check Consult professional personnel, especially when complementing electrolyte (dilute sulfuric acid).

  • Page 21: Ⅶ. Inspection After Operation

    Steering Operation handle Degree of tightness and rotary flexibility. system Oil pipe Leakage or not. Lifting Hydraulic oil Appropriate oil quantity. system Lifting cylinder Whether there is any oil leakage. Pins, screws and all the Check all the fasteners of the truck’s wheels, i.e. fasteners pins or screws, loose or not.
  • Page 22 Notice All the repair work shall be carried out by professional personnel. Please contact the Dealer of our company if you need to adjust or replace the components. 1 Precautions during maintenance: Notice The components for replacement shall be produced completely by our company. When replacing components of the truck, the components with the same safety requirement with the original design shall be used.
  • Page 23 storage battery by the professional personnel before the first use. First, place the truck to the site with good ventilation, open the lid of storage battery box, and open all the top plastic lids of storage battery. The plastic pot with storage battery electrolyte inside is raised using plastic funnel, and the electrolyte is poured into the storage battery in a slow way until the liquid level can be seen.
  • Page 24 6 The inspection and maintenance after 200 hours（Monthly） Besides the weekly maintenance, the following maintenance should be carried out, and when the parts must be adjusted and replaced, please contact with maintenance personnel of our company. (keep monthly maintenance record) Check point Check content Whole status...
  • Page 25 7 Maintenance for 600 hours（every three months） During the maintenance every three months, the monthly maintenance process shall be repeated. When the parts must be adjusted and replaced, please contact with maintenance personnel of our company. Burnish the coarse surface of contactor using sand paper. Contactor Replace according to the status when the function is not well.
  • Page 26 temperature is below 60 degrees. D. At the occasion with variable loading, we advise: All the working conditions mentioned above can use the hydraulic oil LHPISOVG46 in accordance with standard DIN51524T.2 for replacement. The viscidity of this lubricant is very high (mostly used hydraulic oil).
  • Page 27 11 Maintenance period of consumables and partial parts: Items Maintenance content Maintenance period Remarks Bearings of fork Replacement 1200 hours wheel Fork wheel Replacement 1200 hours Replace when finding out Seals Replacement 1200 hours damage Gearbox Replacing lubricant grease 1000 hours Hydraulic oil Replacement 1000 hours...

  • Page 28: Ⅸ. The Store And Transportation Of Forklift

    Ⅸ. The store, transportation and loading of truck: 1 The store of truck: If the electric pallet truck is not used for over two months, it should be placed in the room which is in good ventilation, no frost, clean and dry; also the following measures should be taken: Clean the truck thoroughly.

  • Page 29: Ⅺ. The Disassembly And Assembly Of Some Parts

    Ⅺ. Common faults and troubleshooting: Faults Possible cause Trouble shooting Clean or replace the oil-absorptive The oil-absorptive filter is blocked filter The oil-absorptive tube leaks and the oil are Fasten the tie-in, check the oil level, or foaming. add some oil. Abnormal noise Contact maintenance personnel of our...
  • Page 30 The friction plates of the electromagnetic Replace brake are damaged. Inching switch is damaged or ineffective Tighten it or replace it connection. Brake cannot work Steering potentiometer is damaged or Tighten or replace it after adjustment loosened. Consult the maintenance personnel of Malfunction of controller our company.
  • Page 31 Hydraulic principle diagram Hydraulic principle diagram...
  • Page 32 Electric principle diagram...

  • Page 33: Ⅻ. Common Fault And Trouble Shooting

    Ⅻ. Common faults and trouble shooting 1234 programmer fault menu and LED status display format There are two LED lights (Red and Yellow) on the case of controller. The two LEDs have four different display modes, indicating the type of information they are providing. DISPLAY STATUS Neither LED illuminated...
  • Page 34 5. See 1311 menu Monitor. Battery: Capacitor Voltage. 6. Blown B+ fuse or main contactor did not close. Severe Overvoltage (Shutdown Main Contactor; 1. Battery Menu parameters are misadjusted. Shutdown Motor; 2. Battery resistance too high for given regenerative current. 1，8 Shutdown EM Brake;...
  • Page 35 2. Motor Temperature Control Menu parameters are mis-tuned. 3. See 1311 menus Monitor. Motor: Temperature and Monitor. Inputs: Analog2. 4. If the application doesn’t use a motor thermistor, Temp Compensation and Temp Cutback should be programmed Off. Motor Temp Sensor Fault 1.
  • Page 36 Shutdown Motor; 3. An alternate voltage path (such as an external pre charge resistor) is Shutdown EM Brake.) providing a current to the capacitor bank (B+ connection terminal). 1. Main contactor did not close. Main Contactor Did Not Close 2. Main contactor tips are oxidized, burned, or not making good (Shutdown Main Contactor;...
  • Page 37 Shutdown Motor example, if a user changes the Throttle Type this fault will appear and Shutdown EM Brake) require cycling KSI before the vehicle can operate. 5， 1- 1. These faults can be defined by the OEM and are implemented in the OEM Faults 6，7 application-specific VCL code.
  • Page 38 Shutdown Motor.) Encoder Characterization Fault Shutdown Main Contactor; 1. Encoder characterization failed during the motor characterization 8，8 Shutdown Throttle process. Shutdown EM Brake; 2. Motor encoder pulse rate is not a standard value (32, 48, 64, 80 ppr). Shutdown Motor Motor Type Fault (Shutdown Main Contactor;...
  • Page 39 Appendix 1 ISO3691 Motor industrial vehicle—Safety Norms The Second Part Safety Norms of motor industrial vehicles in service, operation and maintenance Safety rules for the user and driver In order to use the motor industrial vehicle well, this part set up some rules. The 14.1 is applied to the user, the 14.2 is for the driver.
  • Page 40 The driving type high –lift truck should be mounted with protection cabane, except for the condition where the load could not drop onto the driver. When convey the load maybe fall to the driver using high –lift truck, should adopt shielding shelf with enough height, weight and the opening size is small enough to prevent the entire load or part of them from falling onto the driver.
  • Page 41 grade, steep slope, narrows channel and low roof board. The outline or the borderline must be clear. In the road where it is easy to meet the stepping truck, the width of the channel should be adjusted. Advising the grade of the channel should not over 10%, the top and the bottom of the slope should transit smoothly, to prevent the load vibration or the bottom of the truck colliding the ground.
  • Page 42 for equipped with special device and the driver has passed the train to use the device. 14.2 Applied to the driver The safety operating of the industrial truck lies on the control manner of the driver ro a considerable degree. The safety rules applied to the drives are as follows: general rule;...
  • Page 43 When stacking, the mast should tilt backward to ensure the stability of the load, approach the goods pile slowly. When the truck approach and face to the goods pile, it is necessary to adjust the mast to the vertical location, and lift the load a little higher than the height of the pile. Then running backward the truck or if using reach truck, extends the fork and descend it to unload the goods.
  • Page 44 When the vehicle is running, the driver must not let his body outside the contour line of the truck. When turning, if there are some other trucks or pedestrians, the driver must issue warning signal. The driver must comply with all labels about ground load carrying capacity and requirements of other instructive labels.
  • Page 45 away from the elevator (lifter). After the bridge box floor of the elevator (lifter) is even to the ground, the truck should slowly drive in as the positive direction. It should be the load go into the elevator (lifter) first not the driver, this is specially adapted to the walking type truck.
  • Page 46 the leak in the connection of valve or screw-threaded joint; ） The deterioration, damage or lose of the flexibility seal in the connection of prime or air ） feed. If finding the above defect and/or damage, the container should not be used until repaired. The truck which is driven by liquefied petroleum gas is over night or stay indoor for a long time and the liquefied petroleum gas container stayed on the truck, it is necessary to close all of the feed valves on the container.
  • Page 47 15.2.9 Make sure that all the nameplates, indicator boards and labels (pattern) are clear and legible. 15.2.10 Inspection shall be taken for fuel oil system and auxiliary fittings to see if there is any leakage. Soap bath shall be used for leakage inspection of liquefied petroleum gas system. Truck must leave the working site in case of any leakage in fuel oil system.
  • Page 48  Maintenance and repairing recording card: Maintenance Maintenance Items Maintenance part Material used Remarks time personnel  Customer advisement feedback: Time Items Trouble location Fault cause Trouble-shooting Remarks occurred...

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