Hyundai 12ESH Operation Manual
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Hyundai 12ESH Operation Manual

Electric stacker
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12ESH
Electric Stacker
 Operation Manual
 Service Manual

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Summary of Contents for Hyundai 12ESH

  • Page 1 12ESH Electric Stacker  Operation Manual  Service Manual...
  • Page 2 1．When lift height of 12ESH is below 2500mm (including), the maximum load is the rated load; overloading is strictly prohibited; 2．When lift height of 12ESH stacker is above 2500mm (excluding), the load of truck shall decrease. Refer to the load curve for detailed values.

  • Page 3: Table Of Contents

    Contents 1. Outline drawings ..............................1 2. Brief Introduction of Structure ....................... 3 3. Safety Norms ................................ 3 4. Putting into Use for the First Time ....................... 8 5. Instructions for Use and Operations ....................9 6. Use, Maintenance and Charging of Storage Battery ............... 12 7.
  • Page 4 Brief Introduction: 12ESH series electric pallet stackers adopt storage battery as its power source, AC motor as power, the truck is driven to travel through gear transmission, forks lift through hydraulic transmission and DC motor, pushing oil cylinders to move up and down to lift forks and cargo.

  • Page 5: Outline Drawings

    1. Outline drawing...
  • Page 6 12ESH Electric Stacker Manufacturer HYUNDAI Model 12ESH Electric (battery) Driving mode: electric (battery), diesel, Chara Walkie Operation mode: manual, walkie, stand gasoline, fuel cterist Rated load Q(kg) 1200 driving, seated driving, order picking Load center distance (mm) Front overhang (mm)

  • Page 7: Brief Introduction Of Structure

    2. Brief Introduction of Structure (Refer to structural drawings and schematic drawings of main parts) This truck is mainly composed of truck frame, mast, forks, lift oil cylinder, operation handle, steering gear, driving wheel, battery pack, hydraulic power unit and electric control system. 3.
  • Page 8 3.1 Norms for safe operations ⑴ Training of drivers Attention Even for trucks with the same technical parameters, they may differ in characteristics such as braking and accelerated speed. Therefore, do not drive the truck until you have got familiar with all the operations. ⑵...
  • Page 9 B. Without written permission of our company, it is not allowed to modify the truck or add any device. Modifications on the truck may influence its safe operations. ⑹ Set up safe operation procedures: Before use, please set up procedures for safe operations, and take safety into full consideration. ⑺...
  • Page 10 Attention When driving reversely, make sure there is nobody around the truck. Attention When driving in narrow aisles, it should be led by other people. Attention At crossroads or other sight-blocked places, the driver should stop the truck, and start again after making sure there is nobody around.
  • Page 11 （3） Do not drive by the road side. Attention Make sure there is enough distance between the truck and the roadside or the platform edge. When driving on narrow roads or platforms, must keep a certain safe distance from the edges to prevent the truck from falling.

  • Page 12: Putting Into Use For The First Time

    platform, make sure that the lift or platform has adequate bearing capacity, their structures are suitable for the stacker, and that you’ve acquired permission from user of equipment. Make inspections before operations. When the stacker enters lift, let cargo enter first. Choose a proper parking position to avoid collision with walls. If any personnel should use the lift at the same time, he or she shall not enter until the stacker has been parked well.

  • Page 13: Instructions For Use And Operations

    a) Check whether the equipment is complete and in normal condition. b) Install the battery. Pay attention not to damaged the battery cable. 4.1.5 Adjust the characteristic curve of charger (charging curve). 4.1.6 If the stacker has been parked for an extended period of time, the wheels may be a little bit flattened. When the stacker has travelled for a while, it will recover automatically.
  • Page 14 5.1.3 Check whether braking is normal, whether lifting, lowering, travelling forward/backward and other movements are normal, and whether emergency reverse movement is normal. The methods are specified in figure 2. Emergency reverse button Slow button Speed acceleration button Horn Elevator button Speed elevator button Fig.2 Warning...
  • Page 15 in area B. 5.2.2 As shown in left figure 2, there is a slow button on operation tiller. When press the slow button and rotate the acceleration knob, the truck will travel with low speed. Such a condition is suitable for turning, stacking and entering/exiting cargo shelves.

  • Page 16: Use, Maintenance And Charging Of Storage Battery

    5.3.3 If any personnel is pushed against a wall or other object when the truck travels forward, you only need to press the emergency reverse button on top of operation handle, then the truck will travel reversely automatically to prevent damage to human body.
  • Page 17 of the second stage to continue charging. When charging, the temperature of electrolyte shall never exceed 45℃. When the temperature rises nearly to 45℃, reduce the current by half or stop charging temporarily. After the electrolyte temperature reduces to below 35℃, continue charging, however the charge time needs to be extended properly.
  • Page 18 6.3 Keep and storage The storage battery shall be kept in clean, dry and ventilated warehouse within the temperature range of 5 to 40℃. The valid storage period is 2 years. Within the storage period, keep the battery according to the following requirements: a.

  • Page 19: Inspections Before Operations

    7．Inspections Before Operations In order to achieve safe operations and keep the truck in good conditions, full inspections on the truck is required before operating, which is a legal duty. Contact our sales department timely if any problem is discovered. 7.1 Inspection points and contents Check point Check content...

  • Page 20: Inspections After Operations

    8．Inspections after operations After operations, wipe out dirt on the truck, and conduct the following inspections: Keep all the warning signs, nameplates, warning labels and other image-text signals complete and clear. Such signals have certain guiding, reminding and warnings functions for operators. Check whether there is any distortion, damage or breaking condition.
  • Page 21 ⑵ Precautions before maintenance: Attention No smoking. Make self-protective measures. Wipe out the leaked oil timely. When add lubricating oil, first clean the dirty oil or dust on the joint with a brush or cloth. Except for certain situations, turn off the key switch and plug out the power socket.
  • Page 22 9.4 Inspection according to needs Clean the truck. Check and fasten each fastener. Check wearing condition of wheels. 9.5 Inspection and maintenance after 50 hours (weekly) Pull the operation handle to make the handle switch between area A and B; the brake has sounds of absorption.
  • Page 23 Oil pipe The oil pipe leaks or not. Hydraulic oil Proper amount of oil. Lift oil cylinder Leaks or not. Electrolyte Liquid level, density, degree of cleanness Plug Functions, damaged or not Key switch Functions Contactor Contact and functions Micro switch Functions Storage battery;...
  • Page 24 9.7 Maintenance for every 600 hours (three months) When conducting maintenance of every three months, repeat the monthly process. If it’s necessary to adjust or replace spare parts, please contact repair personnel of our company. Polish uneven contacts with abrasive paper Contactor Replace when it fails to function well Motor...

  • Page 25: Loading, Unloading, Transportation And Storage Of Truck

    accordance with DIN51524T.2. This kind of lubricating oil has very high viscosity (mostly applied to hydraulic oil). When the hydraulic oil is difficult to purchase, engine oil SAE20W/20 can substitute hydraulic oil HLP68. （2） Gear oil: Hypoid gear oil 85W-90 (GL-5) （3）...

  • Page 26: Replacing Battery

    10.2 Transportation of truck If the truck is to be transported for a long distance, support the end of the truck which nears the operator with wood beams, to make the drive wheels of the truck away from the ground, and fix the two front wheels with wedge blocks.
  • Page 27 or bad contact between commutator and carbon brush ③ Coil of travelling motor disconnected Repair or replace bad contact ④ contact performance Repair or replace contactor ⑤ MOSFET circuit plate faulted Repair or replace ① Contactor poor contact Stacker can only travel Repair or replace performance or burnt forward (or backward)
  • Page 28 ③ Roller wheel of mast stuck Repair or adjust ④ Guide rod of mast crooked Repair or adjust ⑤ Return oil hole block Clean ⑥ Solenoid valve of hydraulic pump out Exclude fault of solenoid of control valve ① Some single cell damaged Repair or replace Terminal voltage of storage ②...

  • Page 29: Common Fault Signals And Troubleshooting

    13. Common Fault Signals and Troubleshooting Fault Code List and Troubleshooting of 1230 Controller LED code 1311 display Fault explanation Fault cause Signal of speed sensor cannot be motor speed encoder 1 False connecting wire of speed sensor of failure detected 2 Controller faulted Motor Failsafe...
  • Page 30 4，1 Service Total Disable Total KSI time up (stop running) Total KSI time up Total driving time up (stop Service Driver Disable Total driving time up (stop running) running) Service Total Expired Set (KSI) service time up Set (KSI) service time up Service Driver Expired Set (driving) service time up Set (driving) service time up...
  • Page 31 Diagnosis of 1207A Controller and LED Fault Table 1，2 HWFALLSAFE Hardware auto-protection 1．Controller damaged failure 1，3 M-FAULT M-output short circuit 1．M﹣output short circuit to ground 2．Direction contactor not close 3．Direction contactor closes slowly 4．Short circuit of inner motor to ground 1，4 SRO function fault 1．False sequence of KSI input, brake input and...

  • Page 32: List Of Accessories, Spare Parts And Wearing Parts

    Refer to attached figure 1 for hydraulic schematic drawing Refer to Electric Operation Manual for electrical part Refer to attached drawing 2 for exploded drawings 16．Packing List Packing List of 12ESH Electric Stacker Consignee: Manufacture NO.: Contract NO.: Manufacture date:...
  • Page 33 2．Accessories and Spare Parts Name Use position Specification Q’ty Remarks Open lock Fuse Electric part Fuse Electric part 100A Fuse Electric part 180A Seal ring Oil cylinder UHS27 O-seal ring Oil cylinder 45X2.65 O-seal ring Oil cylinder 14X2.65 Combination ring Oil cylinder inlet Dust ring Oil cylinder...
  • Page 34 Hydraulic Principle Diagram...
  • Page 37 CURTIS 1230E CONTROLLER (Serial No. : #20128138~ )

  • Page 38: Appendix Iso3691 Motor Industrial Vehicle-Safety Norms

    Appendix 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 39 When the truck mounted attachment working without load, it should be viewed as partial load. 14.1.4.3 The protection requirement and protection equipment The truck should painted the color differing from the surrounding circumstance. 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.
  • Page 40 If the truck is in operation (transport) and the load block off the sight, when the vehicle is operating, the load should located on the backward of the truck operation direction. For example: in some conditions (for example stacking and climbing), when the vehicle is operating, the load is required on the forward of the vehicle operation direction.
  • Page 41 The motor industrial vehicle could not carry passengers, except for equipped with the facility for the passengers sitting. The driver should pay special attention to the operating circumstance, including the person nearby other staves and fixed or moving substances, and it is necessary to watch out for the passerby at any moment. No matter whether there is load on the lifting part of the truck, it is forbidden anyone passing or standing under the lifting part of the truck.
  • Page 42 The fork should insert into the bottom of the load as possible. But pay attention to not make the fork tip touch the substance except the load. Then lift the fork to the enough height to move the goods. Further lift the fork, make the goods away from the pile exactly. If the mast can tilt backward, the fork should tilt back properly to stabilize the load.
  • Page 43 fork-lift truck , stride- truck and platform carrying vehicle) moves, the load surface must be in a upgrade direction. F) When the truck works on various slopes, the load and the load bearing device must tilt backward (if possible), and the driver can only elevate the load’s height that is enough for running through the road surface and local barrier.
  • Page 44 could not start up. 14.2.4.2.2 Liquefied petroleum gas fuel (liquefied petroleum gas) Only the personnel trained and appointed can refuel or change the liquefied petroleum gas container. The person charging for refuel liquefied petroleum gas should wear protective suit (that is to say long sleeve unit and glove).
  • Page 45 kept within safe operation condition. 15.2.3 Regular inspection shall be taken for safety protection shelf and safety devices, which shall be kept within safe operation condition. 15.2.4 Regular inspection and maintenance shall be taken for all the hydraulic systems. Inspection must be taken for oil cylinder, valve, and other similar components to ensure that internal leakage or external leakage would not develop into a dangerous condition.
  • Page 46 Record card for repair and maintenance Item Position Material used Personnel Remarks Item Customer feedback Item Time Fault position Cause Troubleshooting Remarks...

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