Hyundai 20EDPR Operation Manual
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Hyundai 20EDPR Operation Manual

Electric pallet truck
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20EDPR
Electric Pallet Truck
 Operation Manual
 Parts Catalogue
1

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Summary of Contents for Hyundai 20EDPR

  • Page 1 20EDPR Electric Pallet Truck  Operation Manual  Parts Catalogue...
  • Page 2 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. If there is anything in the manual that is not consistent with the actual 。...

  • Page 3: Table Of Contents

    Ⅱ．Forklift introduction ....................1 1. range of application ....................1 2. service environment ....................1 3. technical parameters ....................1 3.1 structure ....................... 2 3.2 main technical parameters (20EDPR Electric Pallet Truck) ........ 2 Operating instruction ....................7 Ⅲ. 1.Safety norms……………………………………………………………………………………………..………..9...

  • Page 4: Ⅰ．specified Use

    Appendix III ........................32 Ⅰ．Specified use the forklift truck is introduced for a ground conveying equipment, suitable for lifting and transporting goods. Must be in strict accordance with the provisions of the operating instructions in use, operation and maintenance of forklift. It is used for any other purpose, which are not in conformity with the provisions operation behavior, can lead to injuries and fork lift truck or other property damage.

  • Page 5: Ⅱ．forklift Introduction

    Ⅱ．Forklift introduction 1. Range of application 20EDPR 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 20EDPR Name ● Steering mechanism ● Instrument ● Electric lock ● Handle ● Guardrail ● Hydraulic power unit ● Drive unit ● Pedal ● Electric control assembly ● Battery ● Emergency power disconnect ● Mast assembly ● Lift oil cylinder ●...
  • Page 7 support bearings. The system is used to control travel direction of the truck. （3）Braking: The brake of this truck is electromagnetic. When the accelerator pedal is released, the electromagnetic arrester will be out of power and braked. When the accelerator is released during the traveling of the truck, the controller will carry out electric brake at first.
  • Page 8 unexpected condition. ④ Slow button: When this button is pressed, the truck will travel at an extremely slow speed. This button is applicable for operation on especially narrow field or on the condition that the truck needs to be accurately located. （5）...

  • Page 9: Main Technical Parameters (20Edpr Electric Pallet Truck)

    3.2 Main technical parameters (20EDPR Electric pallet truck)
  • Page 10 Manufacturer(abbreviated) 20EDPR Model Driving type：Electric(Storage battery), Electric diesel, gasoline, fuel gas Operation type （Manual, Walking, Stand driving, Seat Standing driving ,Order picking） Q(kg) 2000 Rated load Rated load of the mast Q(kg) 1000 Rated load of the rocker arm Q(kg)
  • Page 11 Lift motor power Battery voltage/rated capacity V/Ah 24/240 Battery weight Battery dimension（LXWXH） 750× 170× Noise level at operator’s ear, according to DIN12053 dB(A) 3.3 Installation position of warning label and nameplate Name Remarks Foot warning label Operating warning label Instruction lable of maintenance of the battery Nameplate III.Operation instruction...

  • Page 12: Safety Norms

    Overloading operation is forbidden. As for goods carrying and operation, center of gravity of the goods must be within range of the two forks. It is forbidden to transport loose goods The truck shall travels slowly when forks pass in or out of pallet. It is strictly forbidden to press the lifting or lowering button during the traveling of the truck.

  • Page 13: Safety Operation Specification

    truck is damaged, the noise may be amplified. （5） Integrity of the truck shall be realized： Warning Do not make modifications on the truck. Please observe safety rules and regulations of your working place during operation, inspection, and maintenance of the truck. Unauthorized truck modification is not permitted.

  • Page 14: Drive And Operation

    person at both sides. F Keep concentration when operating truck. Caution The driving mechanism of truck is installed on the backside. Due to this difference from common vehicles, the backside of truck swings comparatively fast when turning around. For this reason, to prevent collision with other objects nearby the backside of truck, do drive or turn slowly.

  • Page 15: Driving

    Check point Check content When the operation handle is turned, with Operation handle the handle switching between area A and B, Braking there is a noise from the brake. system The clearance between brakes should be Brake clearance kept between 0.2mm and 0.8mm. Operation handle Degree of tightness and rotary flexibility.
  • Page 16 position. When the operation handle is turned to area B and accelerator knob is rotated slowly, the truck will start gradually. The greater the accelerator knob is turned, the faster the truck travels. Warning When forking goods or moving goods, never rotate the accelerator knob rapidly to speed up the truck abruptly.
  • Page 17 • drive the truck near the goods shelf (the fork head is in 300mm distance from the good shelf), press the lift button, adjust the fork height into place, insert the fork slowly as deep as possible into the goods pallets, press the lift button, operate the handle lifting the goods to the height that the bottom of the pallet is 100mm over the shelf, slowly drive the truck, so that make the goods out of the shelf (the fork head is in 300mm distance from the shelf), press the lower button, lower the fork down to about...
  • Page 18 Ⅳ．Maintenance, charge and replacement of battery Standard configuration is external charger and the optional is built in charger. Charging ： operation method as follow Outer charger Charging ways for outer charger： Open the cover,1, pull out the charging socket from main circuit；2，connect with charging plug of battery and charger ；3，put the battery socket into two-phase AC power supply；4,open the power switch;charge after a few seconds.

  • Page 19: Initial Charge

    Warning Hydrogen is aggregated in the battery box when charging. For this reason, the charging condition shall be good ventilated. In avoidance of explosion and fire disaster, open flame is forbidden. 1. Initial charge （1）Initial charge should be conducted for batteries that have never been used. Before the initial charge, the surface of the batteries should be cleaned and the batteries should be examined for damage.

  • Page 20: Use And Maintenance

    electrolytic solution density of the batteries should be examined during the last period of charging. If there is inconsistence, adjust with distilled water or sulfuric acid with a density of 1.40. The electrolytic solution density and the liquid surface should be adjusted to the stipulated value within two hours in the charging state.

  • Page 21: Operation Of Electrolyte

    pressed. d. The batteries must not be stored with electrolytic solution. When it is required in special situation that the batteries must be stored with electrolytic solution, the batteries should be fully charged and the density and the liquid surface of the batteries should be adjusted to the stipulated values.

  • Page 22: Replacement Of Battery

    8. Replacement of the battery The weight of battery pack is about 240kg, and the replacement procedure of storage battery is as follows: 1. Open the side door of storage battery and take it down. 2. Pull down the socket connector of storage battery from the truck. 3.

  • Page 23: Ⅴ. Maintenance And Repair

    Ⅴ. Maintenance and repair 1. Maintenance 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 All the repair work shall be carried out by professional personnel Please contact the sales department of our company if you need to adjust or...

  • Page 24: Daily Inspection

    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. After all the storage battery is filled, conduct initial charge to the storage battery timely according to the operation requirements of initial charge 4.1 1.3 Daily inspection...
  • Page 25 When the operation handle is turned, with Operation handle the handle switching between area A and B, there is a noise from the brake. The clearance between brakes should be Steering Brake clearance kept between 0.2mm and 0.8mm. system, Operation handle Degree of tightness and rotary flexibility.
  • Page 26 Decelerate Replace the gear oil Oil filter clean Clean the dirt and dust on friction plates of the brake, meanwhile check the Brake wearing status of the friction plates. Replace hydraulic oil. Check that whether there is any leakage in the lifting Hydraulic system cylinder or not and replace the seals when necessary...

  • Page 27: Structure Of Lift Oil Cylinder And Wearing Parts(Support Leg)

    1.7 Structure of lift oil cylinder and wearing parts(support leg)： 1. plunger 2. dust ringDH35 3. O-rings 35.5X2.65 4. O-rings 42X2.65 5. seal ring UHS35 6. guide sleeve 7. Oil cylinder 8. piston 9. guide ring 10. semi-ring 11.bowl washer 12. circlip for shaft 20 Structure of lift oil cylinder and wearing parts(forks)：...
  • Page 28 Strainer of hydraulic Cleaning 1000h reservoir Check for carbon brushes Driving motor 1000h and bearings Check for carbon brushes Steering motor 1000h and bearings Check for carbon brushes Oil pump motor 1000h and bearings...

  • Page 29: Common Faults And Trouble Shooting

    Common faults and trouble shooting: 1. Mechanical faults Faults Possible cause Trouble shooting Clean or replace the oil-absorptive The oil-absorptive filter is blocked filter The oil-absorptive tube leaks and Fasten the tie-in, check the oil level, the oil are foaming. or add some oil.
  • Page 30 The electromagnetic brake is out Check the circuit. of electricity. Not release The clearance of the after braked electromagnetic brake is too Adjust the brake clearance to 0.2mm. large. （1） Adjustment methods of safety valve pressure The pressure of safety valves has already been adjusted when the truck is ex-factory.
  • Page 31 Hydraulic principle schematic...
  • Page 32 （2） Adjustment of the brake clearance ①Hollow screw ②Fitting screw ④spline sleeve ③Coil ⑤Friction plate ⑧Mounting screw ⑥Spring ⑦Iron ⑨Mounting cover plate ⑩Clearance The brake structure is indicated as the Fig on the right. After being used for a while, the performance of the brake may decline with the wearing of the brake block or the brake plate can’t be released.
  • Page 33 The disassembly of the brake is shown as the following picture, use tools to loose screw 8.
  • Page 34 2. Electrical faults...
  • Page 35 1311 DISPLAY EXPLANATION POSSIBLE CAUSE CODE 1 Incorrect or ineffective speed sensor The speed sensor signal motor speed encoder wiring. can’t be detected. 2 Controller defective. 1 Speed sensor malfunction. The motor speed is not in Motor Failsafe 2 The electromagnetic brake of motor is not the normal scope.
  • Page 36 Electromagnetic brake 1 Brake coil shorted or open. 3，3 Brake Fault fault. 2 Brake driver fault. Total driving timer has Total driving timer has expired. Service Total Disable expired. 4，1 Setted (KSI) service timer Setted (KSI) service timer has expired. Service Driver Disable has expired.

  • Page 37: Ⅵ. The Store, Transportation And Loading Of Truck

    VI. The store, transportation and loading of truck 1. Loading and unloading of truck: Before loading the truck, check out the nameplate for the total weight of truck to choose appropriate hoisting handling equipment. The hoisting of truck shall be kept level, and landing shall be kept slow and stable.
  • Page 38 Technical documents, Accessory bag accessories and spare parts Note：1．The following documents are in the file bag ① 20EDPR Electric Pallet Truck operating instruction 1 volume ② Packing list 1 copy ③ certificate of quality 1 copy Accessory and spare parts...
  • Page 39 Appendix II Maintenance and repairing recording card: Maintenance Maintenance Maintenance Items Material used Remarks time part personnel...
  • Page 40 Appendix I Customer advisement feedback Time Trouble Items Fault cause Trouble-shooting Remarks occurred location...

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