Hyundai 15EST Operation Manual
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Hyundai 15EST Operation Manual

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15EST
Electric Stacker
 Operation Manual

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Summary of Contents for Hyundai 15EST

  • Page 1 15EST Electric Stacker  Operation Manual...

  • Page 2: 1．Outline Drawing And Main Technical Parameter

    According to ISO 3691 “Safety Specification of Motor Industrial Vehicles”, load capacity and lifting height of our CDD Electric Stacker are stipulated as follows: 1．——When the lifting height of 15EST stacker is below 2500mm (including2500mm), the maximum load capacity is the rated capacity. Overloading is prohibited.

  • Page 3: Table Of Contents

    Contents 1．Outline drawing and main technical parameter………………………..…….1 2．Brief introduction of structure……………………………..………….…………..6 3．Safety specifications…………………………..…….……………….……………….6 4．Initial operation …………………………………………………………………………12 5．Use and operation instruction………………………………………………………12 6．Use, maintenanc and charging of storage battery………………………..16 7．Inspection before operation …………………………….………..……………..19 8．Inspection after operation…………………………………….…….……………….19 9．Periodic maintenance and upkeep…………………………..……..…………….20 10. Storage, transportation, and loading&unloading ……………………………25 11．Replacement of storage battery…………………………..………….....25 12．Common faults and troublshooting………........26 13．Common faults signal and trouble shooting………………………....28...
  • Page 4 Appendix： 《 Safety Specifications of Motor Industrial Vehicles 》 Brief introduction ： CDDR electric pallet stacker adopts storage batteries as the dynamic source and a AC motor as the driving force, traveling through gear transmission. The lifting of the fork relies on the DC motor and the hydraulic transmission system.
  • Page 5 Outline drawing 15EST Outline drawing...
  • Page 6 15EST Electric Stacker Manufacturer(abbreviated) HYUNDAI Model 15EST Driving mode Electric Driving mode Pedestrian Rated load Q(kg) 1500 Load center distance (mm) Load distance (mm) Wheel base (mm) 1420 Service weight(with battery) 1090/1210/1230/1250/1415/14 Axle load, front/rear, laden 1470/1310 60/1500 Axle load, front/rear, unladen...

  • Page 7: 2．Brief Introduction Of Structure

    2． Brief introduction of structure (See also the structure diagram and the principle diagram of the major parts) The stacker mainly consists of frame, mast, fork, lifting oil cylinder, operation handle, steering device, driving wheel, storage battery pack, hydraulic power unit and control system for electrical equipment, etc.
  • Page 8 ⑵ Wear of the driver during truck driving: Notice Please put on safety shoes and protective clothes. Do not wear clothes that are too loose for sake of being caught, which would result in danger. ⑶ Rules that must be observed: Notice Never drive the truck when you are tired or un-concentrated, with an injection of drug, or after a liquor drinking.
  • Page 9 modification or alteration, they shall also make and approve appropriate changes to capacity plate, decals, tags and operation and maintenance handbooks. Only in the event that the truck manufacturer is no longer in business and there is no successor in the interest to the business, the user may arrange for a modification or alteration to a powered industrial truck, provided, however, that the user shall: a) arrange for the modification or alteration to be designed, tested and implemented by an engineer(s) expert in industrial trucks and their safety;...
  • Page 10 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. Notice Ensure no people around the truck when driving backwards.
  • Page 11 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. Decelerate and sound horn when travel by other truck or vehicles.
  • Page 12 Notice Take care to avoid the danger of wind force when loading goods. 10）The operator shall master the traveling speed according to site condition.The truck shall slow down and move at a low speed when turning, at a narrow aisle, passing by swing doors or places where view impeded.

  • Page 13: 4．Initial Operation

    3）Charge: Warning Open flame is forbidden to appear at the charge places, otherwise, explosion or fire disaster can be caused. Make a record of charge. As for the charge method, refer to the part about storage battery operation. 4．Initial operation 4．1 Initial operation：...
  • Page 14 5．1 Before operation: Warning It is strictly forbidden to use faulty truck. 5．1．1 Before operation, please check if the truck is in normal condition: Is there any oil leakage in the hydraulic pipes? Are the supporting wheels able to operate normally? Is there any block? The trucks with problems are prohibited for operation.
  • Page 15 Warning It is strictly forbidden to turn the accelerator knob fastly to speed up the stacker abruptly during goods transportation. Move the control handle to division A or division C as indicated in Fig.II and press the rise/lowering button on th control handle to see if the lifting and lowering of the fork is normal. Then turn the control handle to division B as indicated in Fig.
  • Page 16 Notice Please check the following items before operation of the stacker: Ensure no goods falling and goods damaged at loading and unloading area. Ensure no goods or objects impeding for safety. As indicated in Fig. II, pull out the general power supply switch, unlock the electric door lock, and drive the stacker to the goods pile nearby.

  • Page 17: 6．Use, Maintenanc And Charging Of Storage Battery

    5．3．3 When the stacker is moving forward and pushing the operator against a wall or other objects, press the emergency reverse button on top of the operation handle and the stacker will automatically move backward to avoid injuring the operator. 5．4 After operation：...
  • Page 18 charge. The temperature of electrolytic solution during the process of charging must not exceed 45℃ and when it is close to 45℃, the charging current should be reduced by 50% or the charging should stop temporarily. Wait till the temperature reduces to 35℃ to continue the charging. The charging time, however, should be properly prolonged.
  • Page 19 6．3 Storage Batteries should be stored in a clean, dry and well ventilated warehouse with a temperature of 5-40℃. The valid shelf life is 2 years. The batteries should be kept according to the following requirements during storage: a. No direct sunshine on the batteries and at least 2m away from heat source. b.

  • Page 20: 7．Inspection Before Operation

    7． Inspection before operation: For the sake of safety operation and good situation of the electric truck, it is compulsory to check the truck completely before operation. Contact the sales department of our company when founding problems. 7．1 Check point and check content: Check point Check content When the operation handle is turned, with the...

  • Page 21: 9．Periodic Maintenance And Upkeep

    9． Periodic maintenance and repair: Comprehensive check for truck can avoid malfunction and ensure the service life. The hours listed in maintenance procedures is based on the cases that the truck works for 8 hours per day and 200 hours per month. For the sake of safety, maintenance shall be carried out according to maintenance procedure.
  • Page 22 9．2 Inspection and maintenance before the new truck put into operation In order to follow the industry related regulations and ensure the absolute security to the truck in the transportation, for new ex-factory truck, it is possible that there is no electrolyte inside storage battery before the first use (except the inland sale).
  • Page 23 9．6 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 24 Adjustment of the brake clearance: 1 Hollow screw 2 Fitting screw 3 Spring 4 Armature 5 Motor shaft 6 Spline housing 7 Friction plate 8 Electromagnetic coil 9 Mounting cover plate 10 Mounting screw 1. The structure of brake is shown as the figure. After a period of use, performance of the brake will decline due to the wearing and tearing of the brake plate.
  • Page 25 9．9 Recommended working medium: ⑴ Hydraulic oil: A. When it is normally loaded, we advise: Hydraulic oil: LHPISOVG46, in accordance with standard DIN51524T.2, the average sustained temperature should between 40 degrees to 60 degrees. B. When it is over loaded, we advise: Hydraulic oil: LHPISOVG68, in accordance with standard DIN51524T.2, the average sustained temperature is above 60 degrees.

  • Page 26: Storage, Transportation, And Loading&Unloading

    10．The store, transportation and loading of truck: 10．1 The store of truck: If the electric pallet stacker 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 27: 12．Common Faults And Troublshooting

    12．Common faults and trouble shooting: Faults Possible causes Trouble shooting ① The fuse of control circuit is burnt out. Replace power switch poor ②The Repair or replace connection or is damaged. stacker ③ Fuse of main circuit is blown. Replace notstart.(The contactor ④The switch of electric lock is in poor...
  • Page 28 ①The gear or bearing has got stuck Clean or replace the Difficult steering of the because of foreign matters. bearing drive wheel, noise and ②There is a gap in the bearing installed Adjust the clearance the motor is overloaded. ③The front wheel bearing is damaged. Replace the bearing Reduce the load ①Overload...

  • Page 29: 13．Common Faults Signal And Trouble Shooting

    12．1 Adjustment methods of safety valve pressure The pressure of safety valves has already been adjusted when the truck is ex-factory. Users shall not adjust the pressure at will. Otherwise it will bring danger to the truck’s hydraulic system and safety.
  • Page 30 KSI,INTERLOCK,F/R 2 Wrong SRO type selected. 3 Direction switch malfunction. 4 Sequencing delay too short. Accelerator voltage is too 2，1 Throttle Wiper High 1 Accelerator is damaged. high. 2 Wrong accelerator type selected. 2，2 EMR Wiring Open EMR wiring fault 1 EMR wire or check wire broken.
  • Page 31 startup. 2 Switch is in M2 position. 5，1 Hardware Failure Hardware failure Controller defective. 5，2 Software Failure Software failure Controller defective. 5，3 Parameters Corrupt Parameters corrupt. Controller defective. 2、1232/1234/36/38 programmer Troubleshooting menu and LED troubleshooting table of status display. On the controller housing ,there has two luminous, red and yellow LED lights, flashing different situations represent different fault conditions, see the table below: Display case Representatives meaning...
  • Page 32 Controller Severe under temperature. controller operates 1. The controller working under extreme temperature conditions (above 95 ℃). over-temperature protection 1，6 temperature (main contactors, 2. Vehicle overloading. motors, electromagnetic brake, the 3. the controller is not installed suitable. governor does not work; full braking 4.
  • Page 33 1. Regenerative braking current makes battery voltage higher and displays the fault, the controller’s overvoltage limit parameters takes effect Overvoltage Cutback 2.Battery voltage parameter setting error. Overvoltage cut (drive torque 2，4 3.when the battery resistance is too high when generates decreases) Regenerative braking current 4.battery connection open when generates Regenerative braking...
  • Page 34 ） Main Open / Short 1. Main contactor coil open or shorted. Main contactor coil open 2. The connection terminals are pollution. short (driving a motor 3. Harness is damaged or connection error. 3，1 electromagnetic brake does 3，2 work) Coil2 Driver Open / Short 1.
  • Page 35 is too high (Governor does not work) Throttle Wiper Low Slide the end of the accelerator input Slide the end of the accelerator voltage is too low. is too low 2 View Monitor menu accelerator input. (Governor does not work) Brake Wiper High Brake potentiometer wiper input is Brake potentiometer wiper voltage is too high.
  • Page 36 OS General (Main contactors, motors, electromagnetic brake, governor, An internal controller failure. interlock, driven and proportional valves do not work 1-4, full braking input) PDO Timeout 1. CAN PDO PDO newsletter receive time is in excess of the PDO CAN PDO timeout accepted overtime period Stall Detect 1 motor stops.

  • Page 37: 14．Lists Of Accessories, Spare Parts And Vulnerable Parts

    14．Lists of accessories, spare parts and vulnerable parts 14.1 Lists of CDDR （without full free lift）accessories, spare parts and vulnerable parts Type & Quantit Name Use position Remarks specification Unlock the electric Key to the electric lock lock With no Charging plug and Matched with the 1 set...

  • Page 38: 15．Structure And Principle Diagrams Of Major Parts

    16．Packing list Packing List of CDDR（without full free lift） Electric Pallet Stacker Consignee: Ex-work No.: Contract No.: Ex-work Date: Net weight Dimension Name Quantity Remarks (kg) (L× W× H) CDDR electric pallet A complete set. stacker Technical documents, Accessory box accessories and spare parts.
  • Page 39 Packing List of CDDR（with full free lift）Electric Pallet Stacker Consignee： Ex-work No.： Contract No.： Ex-work Date： Net weight Dimension Name Quantity Remarks (kg) (L× W× H) CDDRZ electric A complete set. pallet stacker Technical documents, Accessory box accessories and spare parts.

  • Page 42: Appendix I Safety Specifications Of Motor Industrial Vehicles

    Appendix 1 ISO3691 Powered industrial trucks—Safety code The Second Part Safety Code of motor industrial trucks in service, operation and maintenance Safety rules for the user and driver In order to use the motor industrial truck well, this part set up some rules. The 14.1 is applied to the user, the 14.2 is for the driver.
  • Page 43 handwriting clear. 14.1.4.2 Stability The user should pay attention to section 6 of the code, which is about the stability of the truck in the working conditions. When operating correctly, the high lift truck accord with the section 6 is steady, but the incorrect operating or the wrong maintenance could let the truck working unsteadily.
  • Page 44 repairing people should wear protective clothes. All the work of changing the battery should carried out according to the description of user’s manual from the factory. When reinstall the battery, should adopt measures to make the battery connecting, orientation and fixation correctly. Do not put tools and other metal substance on the lidless battery.
  • Page 45 14.1.5.2 Gangplank or transition board All the gangplank or transition board should has enough safety coefficients to bear the truck with load. On the gangplank or transition board should marked the max passing load perpetually. The gangplank or transition board should fixed firmly, to prevent the accidental move, vibration or slide.
  • Page 46 B） transporting (lifting and stacking) rule; C） operating (driving) rule; D） the rule for the driver maintaining the truck. Without regard to the rules maybe conduce: A） the serious danger of damaging the driver or other personnel; B） Damage the materials. 14.2.1 General rule Only the personnel who have been trained and get the qualification of operation are permitted...
  • Page 47 not make the fork tip touch the substance except the load. Then the fork should lift to the enough height to move the goods. C） When conveying high and multi-piece piled goods, it is necessary to tilt the mast back ward a little (if can tilt back) to stabilize the load, and should be careful specially.
  • Page 48 the vehicle is starting. If starting on the limiting position, it is necessary to operate carefully. The load or the device that bears load must be kept at the operating height when the truck is moving. If possible, the load shall be tilted backward when the vehicle is running. Except for stacking operation, it is not permitted to lift the load.
  • Page 49 fork-lift truck, cross-country 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 tiltt 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 50 device to the central position, switch off the power, and tighten the brake, stay steady the vehicle to prevent accidental move or make bold by others without approval. When parking the truck, the fire fighting passage, access stairs and fire fighting passages should keep fluently.
  • Page 51 B） the damage of any kinds of valve and fluid level gage; C） the scraping in the safety valve; D） the damage or the lose of the safety bonnet; E） the leak in the connection of valve or screw-threaded joint; F）...
  • Page 52 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. 15.2.5 Inspection and maintenance shall be taken for storage battery, driving motor, contactor and controller, limit switch, protection device, lead wire and connecting assembly, which shall be...
  • Page 53 would threaten safe performance, effective measure shall be taken. Truck cannot be put into operation before repair. 15.3.2 Protective maintenance, lubrication and inspection shall be taken in accordance with schedule for the truck. Data that are in demand of record shall be carefully kept. Recording card of maintenance and upkeep process: Maintenance Maintenance...
  • Page 54 Customer advisement feedback Occurrence Location of Items Faults causes Trouble-shooting Remarks time faults...

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