Hyundai 20EPR Operation Manual
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Hyundai 20EPR Operation Manual

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 Operation Manual
 Service Manual

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Summary of Contents for Hyundai 20EPR

  • Page 1  Operation 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 ...

  • Page 3: Table Of Contents

    Content Brief introduction……………………………………………………………………………………………..1 Technical parameters Ⅰ. ………………………………………………………………………………..2 Structure description Ⅱ. ………………………………………………………………………………..4 Safety norms Ⅲ. ………………………………………………………………..………………………….6 Drive and operation Ⅳ. …………………………………..……………………………………………11 Storage battery and charge Ⅴ. ……………………………………….…………………………...14 Inspection before operation Ⅵ. …………………………………………………………………..18 Inspection after operation Ⅶ. ……………………………………………………………………18 Periodic maintenance and repair Ⅷ.
  • Page 4 Unauthorized truck modification is not permitted. No modifications or alterations to a powered industrial truck, which may affect, for example, capacity, stability or safety requirements of the truck, shall be made without the prior written approval of the original truck manufacturer, its authorized representative, or a successor thereof.

  • Page 5: Brief Introduction

    Brief introduction ： 20EPR/25EPR series electric pallet truck is powered by storage battery, and driven by motor. This kind of truck travels by means of gear transmission. The fork is lifted by means of DC motor and hydraulic actuation, which motivate hydraulic cylinder up and down to lift fork and goods together.

  • Page 6: Technical Parameters

    I. Technical parameters: 1． ． ． ． 20EPR/25EPR Outline drawing： ： ： ：...
  • Page 7 2、 、 、 、 Main technical parameter Model 20EPR 25EPR Driving model ： Electric(storage battery), Electric Electric diesel, gasoline, fuel gas Driving model （ Manual, Walking, Stand Stand driving Stand driving driving, Seat driving ,Order picking） Rated load Q(kg) 2000...

  • Page 8: Structure Description

    Structure description Ⅱ. ： Structure of the entire truck 1． ： 1 Lifting button 2 Lowering button 3 Horn button 4 Emergency reverse button 5 Steering handle 6 Accelerator knob 7 Guardrail 8 Hydraulic power unit 9 Drive unit 10 Standing pedal 11 Charger；...
  • Page 9 meter resets automatically and continue to time and display. Only if it is connected to battery, LCD hour meter will start working. This instrument possesses high reliability under extremely bad environment. Steering system ⑵ The steering system mainly composes of operation handle, steering device shaft, and floating support bearings. The system is used to control travel direction of the truck.
  • Page 10 the truck will speed up with the increasing of rotation amplitude of the knob. 3） Horn button Horn of the truck will be turned on if you press the button. ： 4） 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: Ⅲ. Safety Norms

    Don’t lay the goods on the truck for a long time! 10) It is strictly forbidden to make sharp turn on narrow aisle. When it is turning, slow down the truck so as to ensure the safety of personnel and goods. 11) Descend the forks to the lowest position when the truck is not used.
  • Page 12 The value of truck noise mentioned in instruction is measured under the condition of new truck running on flat, smooth and hard ground. If the traffic surface is bad or the tyre of truck is damaged, the noise may be amplified.
  • Page 13 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 14 Strictly forbid harsh driving： ⑵ 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: Drive And Operation

    Forbid deflective transportation. Passengers on truck must be forbidden. Never push or pull the handle abruptly Never use the truck as towing vehicle. When transporting over-wide goods, the driver shall be extremely careful to turn slowly to keep balance of the goods.
  • Page 16 d) Turn the operation handle to the position of B area and press the emergency reverse button on top of the operation handle to check that whether the truck can move forward or not. 2. 2. 2. 2. Driving ： Start-up ⑴...
  • Page 17 Transportation operation ⑸ ： Notice Before operating truck, do check the following items: Ensure no goods falling and damaged in the loading area. Ensure no goods or objects impeditive for safety. The following procedure shall be observed for goods transportation： Decelerate when approaching the goods area;...

  • Page 18: Ⅴ. Storage Battery And Charge

    Usage, maintenance and charge of storage battery Ⅴ Ⅴ Ⅴ Ⅴ ..Schematic diagram of charging method Charging operation method: The truck is equipped with a charger. When the truck needs to be charged, first open the cover of battery box to take out the charging plug from the side hole of the truck, then insert the charging plug into the two –phase AC power.
  • Page 19 temperature rise caused by chemical reaction of the electrolyte and let the electrolyte fully penetrates into the pores of the polar plates and the baffles, the batteries should be placed still for 3-4 hours, not exceeding 8 hours. The initial charging can only be conducted when the electrolyte temperature reduces to below 35℃.
  • Page 20 conducted during the process of use is called common charge. 2．2 Common charge: The first stage current of common charge is 30A and that of the second stage is 15A. The charging method is the same as that of initial charge. The charged volume is 130-140 % of the discharged volume and the charging time is about 12 hours.
  • Page 21 5 5 5 5 Operation of storage batteries during the final stage of their lifetime Operation of storage batteries during the final stage of their lifetime ⑴ When the lifetime of storage battery is about to terminate, the electrolyte in single battery reduces very fast. For this reason, distilled water shall be complemented everyday.

  • Page 22: Ⅵ. Inspection Before Operation

    Ⅵ Ⅵ Ⅵ Ⅵ . 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. Check point and check content: 1 1 1 1 Check point...

  • Page 23: Periodic Maintenance And Repair

    Periodic maintenance and repair: Ⅷ Ⅷ Ⅷ Ⅷ ..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.
  • Page 24 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 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...
  • Page 26 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. Contactor Replace according to the status when the function is not well.
  • Page 27 Lubricating grease: ⑶ Lithium grease of type 3 All kinds of depleted hydraulic oil, gear oil and grease will pollute the environment. For this reason, recycle the replaced working medium or treat according to local pertinent regulations 10 Structure of lifting cylinder and wearing parts: 1.

  • Page 28: Ⅸ. The Storage Of The Pallet Truck

    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 Gear box Replacing lubricant grease 1000 hours Hydraulic oil Replacement...

  • Page 29: Ⅹ. The Tow Of The Pallet Truck

    arms to the bottom, in avoidance of damaging the driving wheel, balance wheel and forward wheel. 4 Movement of the damaged truck Towing of the truck is not allowed. As for the movement of damaged trucks, please refer to the operation methods of loading &unloading and transportation mentioned above. Ⅹ.
  • Page 30 Hydraulic principle diagram Hydraulic principle diagram...
  • Page 31 Electric principle diagram...

  • Page 32: Ⅺ. Common Fault And Troubleshooting

    Ⅺ. 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 33 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 EMBrake;...
  • Page 34 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. 1. Motor thermistor is not connected properly. Motor Temp Sensor Fault 2.
  • Page 35 Shutdown Motor; 3. An alternate voltage path (such as an external precharge resistor) Shutdown EMBrake.) is 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 36 1． This is a safety fault caused by a change in certain 1311 parameter Parameter Change Fault (Shutdown MainContactor settings so that the vehicle will not operate until KSI is cycled. For 4，9 Shutdown Motor example, if a user changes the Throttle Type this fault will appear Shutdown EMBrake) and require cycling KSI before the vehicle can operate.
  • Page 37 Shutdown Throttle; Motor_Temperature > 150°C during the characterization process. Shutdown EMBrake; Shutdown Motor.) Encoder Characterization Fault 1. Encoder characterization failed during the motor characterization Shutdown MainContactor; process. 8，8 Shutdown Throttle 2. Motor encoder pulse rate is not a standard value (32, 48, 64, 80 Shutdown EMBrake;...
  • Page 38 The pipeline is broken or leaking. Replace the pipeline or screw down the tie-in. The viscidity of oil is not suitable; the Change the oil. leakage loss is too great. The cause is the same as that of abnormal Refer to the treatment methods for abnormal noise.
  • Page 39 overflow valves. Turn pressure screw left and right until the pressure reaches the specified value. When the screw is turned clockwise, the system pressure increases. While the screw is turned counter-clockwise, the system pressure decreases. 4 After the adjustment, please screw down the locknuts.
  • Page 40 Appendix 1 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 41 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 42 the reverse joint truck from moving suddenly. 14.1.5.3 Lighting When the photometric brightness on the operating field is less than 32LX, the vehicle should equipped auxiliary light. 14.1.5.4 The suspending of the truck The sling should be tied to the lifting spot which the factory appointed. 14.1.5.5 The synchronizing operation of the truck Conveying bulky or heavy load using two trucks simultaneously is a dangerous operating which requires special care.
  • Page 43 sudden starting, stopping and turn over at high speed are forbidden. Except for the requirement of the operation conditions, advising the steering wheel should not put on the limiting position when the vehicle is starting. If starting on the limiting position, it is necessary to operate carefully.
  • Page 44 After the driver leaving, the carrying device must lower to the lowest position, switch off the power, 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 45 for the truck. Data that are in demand of record shall be carefully kept.  Maintenance and repairing recording card: Maintenance Maintenance Maintenance Items Material used Remarks time part personnel  Customer advisement feedback: Time Items Trouble location Fault cause Trouble-shooting Remarks occurred...

This manual is also suitable for:

25epr

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