Hyundai 15ES Operation Manual
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Hyundai 15ES Operation Manual

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15ES
 Operation Manual
 Service Manual

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Summary of Contents for Hyundai 15ES

  • Page 1 15ES  Operation Manual  Service Manual...
  • Page 2 According to ISO 3691 “Safety Specification of Motor Industrial Vehicles”, load capacity and lifting height of our 15ES Electric Pallet Stacker are stipulated as follows: 1．——When the lifting height of 15ES stacker is below 2500mm (including2500mm), the maximum load capacity is the rated capacity. Overloading is prohibited.
  • Page 3 1500kg 1400kg 1200kg 1000kg 800kg 2500 mm 600kg 3000 mm 3300 mm 400kg 3500 mm 4500 mm 5000 mm 200kg 5600 mm 100kg 1000 1.5T LOAD CHART 2000kg 1800kg 1600kg 1400kg 1200kg 1000kg 800kg 2500 mm 600kg 3000 mm 3300 mm 3500 mm 400kg 4500 mm...

  • Page 4: Table Of Contents

    Table of Contents 1．Configuration diagram and main technical parameter…………………….2 2．Brief introduction of structure……………………………..………….…………..7 3．Safety specifications…………………………..…….……………….……………….7 4．Initial operation ………………………………………………………………………..13 5．Use and operation instruction……………………………………………………..14 6．Use, maintenanc and charging of storage battery………………………..17 7．Inspection before operation ………………………………….………..…………..20 8．Inspection after operation…………………………………….…….……………….21 9．Periodic maintenance and upkeep…………………………..……..…………….21 10.
  • Page 5 ： Brief introduction 15ES 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. The up-and-down movement of the oil cylinders lifts the fork and the goods.
  • Page 6 Configuration diagram 1.1 15ES configuration diagram...
  • Page 8 1.2 Main technical parameters（15ES Electric Pallet Stacker） Manufacturer(abbreviated) HYUNDAI Model 15ES Driving model：Electric(Storage battery), diesel, Electric(storage battery) gasoline, fuel gas Driving model（Manual, Walking, Stand driving, seat walking driving ,Order picking） Rated load Q(kg) 1500 Load center distance (mm) Front overhang...

  • Page 9: 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 10 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 11 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 12 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. Notice Driving through the narrow access shall be guided by working personnel. Notice At crossroad or other places impeditive for view, the driver shall not drive until there is no person at both sides.
  • Page 13 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. Avoid driving in places with bad view. Notice Ensure to provide certain clearance between truck and entrance.
  • Page 14 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. And the truck shall keep enough distance with the forklift moving forward. Abrupt stop, sharp turn and overtaking are forbidden at dangerous places or where view is impeded except accidents.

  • Page 15: 4．Initial Operation

    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： 4．1．1 In case of dangerous conditions, the power can be cut off, and the battery plug must be connected to the emergency parking plug of the stacker itself.
  • Page 16 hydraulic pipes? Are the supporting wheels able to operate normally? Is there any block? The trucks with problems are prohibited for operation. 5．1．2 Check if there is any electric power in the batteries with the method indicated in Fig.I. Pull the general power switch out to turn on the general power supply, unlock the electric lock on the handle, check the electric energy meter on the instrument panel of the truck.
  • Page 17 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 the 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 18 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 19 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 20 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 21 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 22: 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 23 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 24 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 25 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 26 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 27 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 28: Storage, Transportation And Loading & Unloading Of Truck

    10． Storage, transportation and loading & unloading 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 29: 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. The stacker can notstart. ③ Fuse of main circuit is blown. Replace (The contactor does not ④The switch of electric lock is in poor...
  • Page 30 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 31 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 32: 13．Common Faults Signal And Trouble Shooting

    13．Common fault signal and troubleshooting 1230 controller fault code and diagnosis list 1311 DISPLAY EXPLANATION POSSIBLE CAUSE CODE The speed sensor signal 1 Incorrect or ineffective speed sensor motor speed encoder can’t be detected. wiring. 2 Controller defective. The motor speed is not in Motor Failsafe 1 Speed sensor malfunction.
  • Page 33 Precharge Precharge fault 1 Controller defective. 2 Low battery voltage. 3，3 Brake Fault Electromagnetic brake fault. 1 Brake coil shorted or open. 2 Brake driver fault. 4，1 Service Total Disable Total KSI timer has expired. Expired total KSI timer. Total driving timer Service Driver Disable...
  • Page 34 main contactor open, electromagnetic brake V. Valve, pump motor traction motor Motor output valve, lifting or VMN HIGH waiting for stop turning, voltage higher start-up traction traction main contactor than expected request open, electromagnetic brake. Valve, pump motor traction motor POWER valve, lifting or waiting...
  • Page 35 DAMAGED damaged/ traction motor traction request (The switch of stop turning, main contactor is main contactor not able to open, close.) electromagnetic brake. Valve, pump motor and traction motor valve, CONTACTOR The main contactor coil waiting for stop turning, lifting or OPEN has been driven, but the start-up...
  • Page 36 brake. Valve, pump motor traction motor valve, LOGIC Overvoltage/Undervoltage start-up, waiting for stop turning, lifting FAILTURE #1 condition has been standby, traction main contactor traction detected. traction open, request electromagnetic brake. Valve, pump motor standby, traction motor traction valve, LOGIC waiting for Motor voltage feedback stop...
  • Page 37 microcontroller. stop turning, main contactor open, electro magnetic brake. Valve, pump motor and traction motor start-up, valve, lifting or ENCODER ERROR waiting Problem on the stop turning, standby, traction traction decoder main contactor traction request open, electro magnetic brake. Valve, pump motor and Input mismatch...

  • Page 38: 14．Lists Of Accessories, Spare Parts And Vulnerable Parts

    14．Lists of accessories, spare parts and vulnerable parts 14.1 Lists of 15ES （without full free lift）accessories, spare parts and vulnerable parts Type & Quantit Name Use position Remarks specification Unlock the...
  • Page 39 14.2 Lists of 15ES （with full free lift）accessories, spare parts and vulnerable parts Type & Name Use position Quantity Remarks specification Unlock the Key to the electric lock electric lock With no Charging plug and Matched with the 1 set...

  • Page 40: 16．Packing List

    16．Packing list Packing List of 15ES（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) 15ES electric pallet A complete set. stacker Technical documents, Accessory box accessories and spare parts.
  • Page 41 Packing List of 15ES（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) 15ES electric A complete set. pallet stacker Technical documents, Accessory box accessories and spare parts.
  • Page 42 ￠10X2 Hydraulic Principle Diagram (standard)
  • Page 43 Solenid Valve Main Motor Hydraulic Principle Diagram (high standard)
  • Page 46 CURTIS CONTROLLER 1232E...
  • Page 47 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 48 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 49 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 50 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 51 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 to drive the industrial truck.
  • Page 52 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. When unloading the goods, it is necessary to descend carefully. If possible, tilt the mast forward a little (or limited)in order to put ready the load and draw out the fork.
  • Page 53 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. This regulation does not apply to truck specially designed that can move with lifting load.
  • Page 54 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 55 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 56 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 57 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 58 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 59 Customer advisement feedback Occurrence Location of Items Faults causes Trouble-shooting Remarks time faults...

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