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Hyundai 12ESN Operation Manual
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Hyundai 12ESN Operation Manual

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12ESN
Operation Manual
Service Manual
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Summary of Contents for Hyundai 12ESN

  • Page 1 12ESN Operation Manual  Service Manual ...
  • Page 2 ******************************************************* According to ISO 3691 “Safety Specification of Motor Industrial Vehicles”, load capacity and lifting height of our 12ESN Electric Pallet Stacker are stipulated as follows: 1． When the lifting height of stacker is below 2500mm (including2500mm), the maximum load capacity is the rated capacity.
  • Page 3 Table of Contents 1．Configuration diagram and main technical parameter…………………….5 2．Brief introduction of structure……………………………..………….…………..7 3．Safety specifications…………………………..…….……………….……………….7 4．Initial operation ………………………………………………………………………..13 5．Use and operation instruction……………………………………………………..13 6．Use, maintenanc and charging of storage battery………………………..16 7．Inspection before operation……………………………………….………………..19 8．Inspection after operation…………………………………….…….……………….20 9．Periodic maintenance and repair…………………………..………..…………….20 10. Storage, transportation and loading & unloading of truck……………….25 11．Replacement of storage battery…………………………..………….....26 12．Common faults and trouble shooting………........26 13．Common faults signal and trouble shooting………………………....29...
  • Page 4 Brief introduction ： 12ESN 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 5 1. Configuration diagram Configuration diagram...
  • Page 6 12ESN Electric Pallet Stacker Manufacturer(abbreviated) Model 12ESN Driving model：Electric(Storage battery), Electric(storage battery) Driving model（Manual, Walking, Stand driving, diesel, gasoline, fuel gas walking Seat driving ,Order picking） Rated load Q(kg) 1200 Load center distance (mm) Front overhang (mm) Tread (mm) 1146...
  • Page 7 Brief introduction of structure 2． (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. 3.
  • 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 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. b) Maintain a permanent record of the design, test(s) and implementation of the modification or alteration.
  • Page 10 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 11 when travel by other truck or vehicles. Avoid driving in places with bad view. Notice Ensure to provide certain clearance between truck and entrance. （3） Never drive too close to roadside: Notice Ensure to provide enough distance between the truck and roadside or platform edge.
  • Page 12 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 13 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. Warning It is strictly forbiddent to operate the stacker without emergency parking plug.
  • Page 14 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. If the zero end grid is bright, it indicates there is no electric power in the batteries and charging should be conducted at once. It is prohibited to operate the truck without electric power as that will greatly reduce the service life of the batteries and even damage the batteries.
  • Page 15 Move the control handle to division B as indicated in Fig.II, press the emergency reverse button on top of the control handle to ckeck that whether the truck can travel backward normally. After the above check, if there is no failure in the truck, it can be put into operation; if there is some failure, please repair it at once.
  • Page 16 put the goods carefully on the shelf. Take the fork away from the goods and drive the stacker slowly to make the fork out of the goods pallet. (The tip of the fork is 300mm from the goods shelf.) Lower the fork until it is 300mm from the ground and drive the stacker away from the shelf.
  • Page 17 Warning There is hydrogen gas accumulated in the battery case during charging. Thus the charging environment requires good ventilation and there should be no flame, otherwise explosion or fire may occur. 6．1 Initial charge 6．1．1 Initial charge should be conducted for batteries that have never been used, i.e. initial charge. Before the initial charge, the surface of the batteries should be cleaned and the batteries should be examined for damage.
  • Page 18 6．2 Use and maintenance 6．2．1 In order to guarantee the service life of the batteries, the batteries in use should be fully charged. Insufficiently charged batteries must not be used. During the process of use, close attention should be paid to the discharge extent.
  • Page 19 6．4 Operation of electrolyte ⑴ Density check The suction type densimeter shall be used to check density. During operation, avoid spilling out the electrolyte, and do wear protection appliance. ⑵ Operation besides check Consult professional personnel, especially when complementing electrolyte (dilute sulfuric acid). ⑶...
  • Page 20 Steering Operation handle Degree of tightness and rotary flexibility. system Oil pipe Leakage or not. Hydraulic oil Appropriate oil quantity. Lifting oil cylinder Whether there is any oil leakage. Pins, screws and all Check all the fasteners of the truck’s wheels, i.e. the fasteners pins or screws, loose or not.
  • Page 21 9．1 Precautions during maintenance: Notice The components for replacement shall be produced completely by our company. When replacing components of the truck, the components with the same safety requirement with the original design shall be used. The lubricating oil and hydraulic oil in use shall be recommended by our company.
  • Page 22 9．4 The inspection according to the need Clean the truck Inspect and screw down each fastener Inspect the damage state of wheels 9．5 The inspection and maintenance after 50 hours （Weekly） When the operation handle is turned, with the steering handle switching between area A and B, there is a noise from the brake.
  • Page 23 Lifting oil cylinder Whether there is any oil leakage or not. Liquid level，specific gravity and cleanness Electrolyte Plug Function, whether it is damaged or not Key switch Function Contactor Contact performance and function Inching switch Function Storage battery, Controller Function charger and Wearing status of carbon brush and selenium electric...
  • Page 24 Burnish the coarse surface of contacts using sand paper. Contactor Replace according to the status when the function is not well. Motor Wearing status of carbon brush and selenium rectifier. Clean the dirt and dust on friction plates of the brake, meanwhile check the wearing status Brake of the friction plates.
  • Page 25 9．10 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 26 11．Replacement of storage battery 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. Pull out the pin of battery case to loosen the battery. 4.
  • Page 27 Adjust or tighten the ①The erection bolt of the fine motion bolt or replace the fine switch looses or is damaged. motion switch. Tighten the bolt or ②The connecting wire The brake does not work repair the side-magnet side-magnet brake is loose or brake.
  • Page 28 ⑥ The electromagnetic valve is out of Shoot the trouble control ① Damage of individual battery Repair or replace Reduced end voltage of electrolytic ② Low level of the electrolytic solution the storage battery solution ③ Foreign matters in the electrolytic (after charged) Replace electrolytic...
  • Page 29 13．Common fault signal and troubleshooting 1230 controller fault code and diagnosis list LED CODE 1311 DISPLAY EXPLANATION POSSIBLE CAUSE 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 30 3，1 Multiplexer Fault Multiplexer malfunction Multiplexer malfunction Misssing or welded main 3，2 Main Contactor 1 Main contactor coil open. contactor. 2 Main contactor stuck closed 3 Welded main contactor 4 Main contactor driver shorted. Precharge Precharge fault 1 Controller defective. 2 Low battery voltage.
  • Page 31 1207A controller fault diagnosis list and status display LED fault diagnosis list 1，2 1．Controller damaged HWFALLSAFE automatic protection of hardware failure fault 1，3 M-FAULT M-output shortcircuit 1．M﹣ output shortcircuit 2．Direction contactor is has no closing. 3． Direction contactor closed too slow 4．Inside motor has short circuit.
  • Page 32 14．Lists of accessories, spare parts and vulnerable parts 14.1 Lists of 12ESN（without full free lift）accessories, spare parts and vulnerable parts Type & Quantit Name Use position Remarks specification Unlock the Key to the electric lock electric lock Electric Fuse equipment...
  • Page 33 16．Packing list Packing List of 12ESN Electric Pallet Stacker Consignee: Ex-work No.: Contract No.: Ex-work Date: Net weight Dimension Name Quantity Remarks (kg) (L× W× H) electric pallet A complete set. stacker Technical documents, Accessory box accessories and spare parts.
  • Page 34 Hydraulic Principle Diagram...
  • Page 37 CRUTIS 1232E CONTROLLER...
  • Page 38 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 39 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 40 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. Without the special approval (for example the truck factory), the electrical motor truck should not change the battery with different voltage, weight or size.
  • Page 41 for moving goods. The gangplank or transition board should have non-slip finishing. On the both sides of the gangplank or transition board, should mounted the facility to prevent the truck from going over it’s edge. When the gangplank or transition board is fixed its location, should adopt measures to prevent the reverse joint truck from moving suddenly.
  • Page 42 The motor industrial truck 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.
  • Page 43 When the truck approach and face to the goods pile, it is necessary to adjust the mast to the vertical location, and lift the load a little higher than the height of the pile. Then running backward the truck Or if using reach truck, extense the fork and descend it to unload the goods. After lifting, start the vehicle, no matter with or without load, it is necessary to operate the brake carefully and placidly.
  • Page 44 When the truck is operating with load, the driver must control turning equipment and brake system slowly and stably. In crossroads and the occasion that would obstruct the driver’s sight or some dangerous occasion, the truck must not exceed other truck moving at the same direction. The driver must avoid the truck rolling over some fluffy object in order to avoid article damages or personnel hurts.
  • Page 45 position. Before a motor-driven industry truck runs on the road vehicle or railroad vehicle, it must be ensured that the floor board can endure all the weight of the industry vehicle, load and the driver. Besides, it is required to check the plank to see if there are crashes, holes or other damages. When the industry truck works on high place or platform, it is forbidden to move other truck by industry truck.
  • Page 46 Before refuel, it is necessary to close the engine, brake the truck and the driver should leave the truck. The open flame and smoking is forbidden during refueling. 14.2.4.2.1 Liquid fuel (for example gasoline and diesel fuel) The truck using liquid fuel should add fuel in the appointed places. Before take away the refueling equipment, cover the filler cap and clear up the excessive fuel, the engine could not start up.
  • Page 47 The top of the battery should keep dry; the connection terminal should keep clean, wipe a little vaseline and screw down correctly. Without approval, the battery of different voltage, weight or size could not replace the former one in the vehicle. When reinstalling the battery, the battery should be put on the correct place.
  • Page 48 filling fuel into all the liquefied petroleum gas containers, to see whether there is the following defective or damage: A） Dent, scuffing, flute; B） Damage of various valves or lever meters; C） Scraps in emergency valve; D） Damage or loss of emergency valve bonnet; E）...
  • Page 49 Recording card of maintenance and upkeep process: Maintenance Maintenance Maintenance Items Material used Remarks time Part personnel Customer advisement feedback Occurrence Location of Items Faults causes Trouble-shooting Remarks time faults...