Hyundai 20EPR-X Operator's Manual

Electric pallet truck

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20EPR-X / 25EPR-X

Electric Pallet Truck

Operator's Manual

WARNING

Do not use the pallet truck before reading

and understanding these operating

instructions.

NOTE:

• Please check the designation of your

present type at the last page of this

document as well as on the ID-plate.

• Keep for future reference.

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Summary of Contents for Hyundai 20EPR-X

Page 1 20EPR-X / 25EPR-X Electric Pallet Truck Operator’s Manual WARNING Do not use the pallet truck before reading and understanding these operating instructions. NOTE: • Please check the designation of your present type at the last page of this document as well as on the ID-plate.
Page 2 FOREWORD Before operating the truck, read this ORIGINAL INSTRUCTION HANDBOOK carefully and understand the usage of the truck completely. Improper operation could create danger. This handbook describes the usage of different electric pallet trucks. When operating and servicing the truck, make sure, that it applies to your type. Keep this handbook for future reference.
Page 3 TABLE OF CONTENTS CORRECT APPLICATION ........................ 4 DESCRIPTION OF THE PALLET TRUCK ..................5 Overview of the main components ....................5 Main technical data ........................6 Description of the safety devices and warning labels (Europe and other, excepting USA) ... 8 Identification plate ........................
Page 4 Checking electrical fuses ......................32 Wheel replacement procedure ....................33 De-energizing of energy stored components................34 11. TROUBLE SHOOTING ........................35 12. WIRING/ CIRCUIT DIAGRAM ......................36 Electrical circuit diagram ......................36 Hydraulic circuit ........................... 38 13. DECLARATION OF CONFORMITY (valid, if sold within the EU) ........... 38 [GB] CE Declaration of Conformity ......................
Page 5 1. CORRECT APPLICATION It is only allowed to use this electric pallet truck according to this instruction handbook. The trucks described in this handbook are self propelled electric power pallet trucks, with electrically powered low height lifting function as well for trucks with mast-lift and initial lift. The trucks are designed to lift, lower and transport palletized loads.
Page 6 2. DESCRIPTION OF THE PALLET TRUCK a. Overview of the main components Fig. 1: Overview main components Safety (belly) button 11. Discharge indicator and charging indicating Tiller Top cover 12. USB port Pin-code panel 13. Load roller Middle cover 14. Main cover Protective arm cover 15.
Page 7 b. Main technical data Fig. 2: Technical data...
Page 8 Table 1: Main technical data for standard version Type sheet for industrial truck acc. to VDI 2198 Manufacturer`s type designation 20EPR-X 25EPR-X Power(battery,diesel,petrol gas,manual) Battery Operator type Pedestrian Q (t) Load Capacity / rated load c (mm) Load center distance...
Page 9 c. Description of the safety devices and warning labels Sticker to read and follow this instruction Warning sticker Capacity sticker Crane hook label Identification plate (ID-plate) Sign oil filling point Indicating sticker Warning information The truck is equipped with an emergency switch (9) which stops all lifting-, lowering-, driving- functions and engages...
Page 10 Sign read and follow this instruction (A) Sign oil filling point (F) Indicating sticker (G) Warning sticker (B) Sign warning stay clear stop truck (H) Capacity sticker (C) Crane hook label (D)
Page 11 d. Identification plate Fig. 4: Identification plate 3. WARNINGS, RESIDUAL RISK AND SAFETY INSTRUCTIONS DO NOT • Put foot or hand under or into the lifting mechanism. • Allow other person than the operator to stand in front of or behind the truck when it is moving or lifting/lowering.
Page 12 • In case of moving the load which overlap the field of view on forward/backward direction use visual assistance from trained personnel 4. COMMISSIONING, TRANSPORTING, DECOMMISSIONING a. Commissioning Table 2: Commissioning data Type 20EPR-X 25EPR-X Commissioning 620 kg 770 kg weight [kg]...
Page 13 Transportation DURING TRANSPORTATION ON A LORRY OR TRUCK ALWAYS FASTEN THE TRUCK SECURELY Lower the forks and park the truck securely. Fasten the truck according to fig. 6 by fixing dedicated lashing belts to each side of the trucks crane hook holes and fasten the other side at the transporting truck.
Page 14 • Check the lifting and lowering functions by operating the buttons. • Check if all bolts and nuts are tightened firmly. • Visual check if there are any broken hoses or broken electric wires. If supplied with a backrest extension, check it for damages and correct assembling. •...
Page 15 After starting the truck by turning on the key switch (10), or by activation from Pin-code panel, move the tiller to the operating zone (‘F’, fig.9). Turn the accelerator button to the desired direction forward ‘Fw.’ or backwards Bw.’(fig. 9). Fig.
Page 16 the truck brakes regenerative until it starts travelling into the opposite direction. The truck brakes, if the tiller is moved up or down to the braking zones (‘B’). If the tiller is released, • the tiller moves automatically up to the upper baking zone (‘B’). The truck brakes until it stops.
Page 17 b. Main functions Truck can be operated only when correct password is typed or card is properly swiped. Please check the administrator password on the separated instruction. Default user password is 1234, you can use it immediately. If you need to change the password, please refer to separated instruction.
Page 18 As standard batteries, the truck is equipped with following liquid acid traction battery- type: Truck Battery standard Voltage Capacity Dimensions Weight 20EPR-X 2 PZS 160/210 Ah 624X212X627 155/185 25EPR-X 3PZS 270/350 Ah 624X284X627 215/255 LEAD-ACID BATTERIES AND LITHIUM BATTERIES ARE ALLOWED.
Page 19 b. Battery indicator Normal Malfunction Fig. 13: Battery indicator The main interface displays as shown in the figure above. Hour meter The digital counter after Hourglass Symbol indicates the working hour of the truck. Battery state of charge It displays the battery symbol and the current battery level. The charge status of the battery is displayed in ten increments.
Page 20 Manufacturer`s type Battery type Capacity specification designation 24 V battery 2PzS-160Ah 24V /SN30A 24 V battery 2PzS-210Ah 24V /SN35A 20EPR-X 24 V battery Li-Ion 100Ah 24V60A 24 V battery Li-Ion 150Ah 24V60A 24 V battery 3PzS-270Ah 24V /SN35A 25EPR-X 24 V battery...
Page 21 d. Description of the lithium-ion battery The lithium-ion battery is a battery with rechargeable cells, the battery is designed for industrial trucks and can withstand related vibrations during operation. The battery is equipped with special connections for charging and discharging operations. Do not try to install or connected improper connectors to the battery.
Page 22 e. Battery Decals Item Description Identification plate Bar code and two-dimensional Warning Label Identification plate and Warning label Item Description Item Description Manufacturer logo Rechargeable logo Battery model Vertical upward packing, transportation Nominal voltage of battery No putting into ordinary garbage bins Rated capacity of battery No long-term exposure to sunshine Battery energy of battery...
Page 23 f. Safety Instructions, Warning Indications and other Notes Safety regulations for handling lithium-ion batteries Do not try to make any repairs or servicing of lithium batteries Risk of electric shock and burning The battery’s charging and discharging connectors have open terminals, avoid any body contacts, contamination or direct contacts with objects which can cause short circuit connection of terminals.
Page 24 recharging of fully charged battery. The charger will not work while battery is fully charged. Potential hazards If equipment is used according to its design purpose, following the correct operations procedures, there are no hazards anticipated. The following hazards can arise in the event of improper use: Physical damage to the battery in case a battery falls or is deformed through impacts.
Page 25 Symbols - Safety and Warnings Caution! Battery short-circuit is prohibited. The battery can be recharged cyclically Vertical upward packing, transportation and use Used lithium-ion batteries must be treated as hazardous waste. Lithium-ion batteries marked with the recycling symbol and the sign showing a crossed- out waste bin must not be disposed of with ordinary household waste.
Page 26 Additional firefighting instructions To prevent secondary fires, the lithium-ion battery must be cooled from the outside. Fluids or solids must never be directed into the lithium battery. Suitable extinguishing agents Carbon dioxide extinguisher (CO2) • Water (not on mechanically opened or damaged batteries) •...
Page 27 Battery lifetime and maintenance The lithium-ion batteries are maintenance-free. Full discharge can damage the battery Self-discharge can cause the battery to fully discharged state. Full discharge shortens the service life of the battery and can cause deep discharge and activation of related safety protocols when battery will not be able to be charged anymore.
Page 28 Faults If any damage is found to the battery or battery charger contact the service provider immediately. Do not open the battery. Disposal and transport of a lithium-ion battery Instructions for disposal Lithium-ion batteries must be disposed of in accordance with the relevant national environmental protection regulations.
Page 29 light use applications once per month. Do not water a battery that has been sitting for an extended period of time with no activity (non-use or not on charge) such as a battery that has sat idle over the weekend. It is best to water a warm battery that has just been fully charged.
Page 30 Disconnecting before the balls come to a complete stop will lead to underfilled cells. Replace dust cover Place dust cover back over the male coupler and place feed tube on top of battery. Fig.20: Replace dust cover 10. REGULAR MAINTENANCE •...
Page 31 a. Maintenance checklist Table 5: Maintenance checklist Inspection MAINTENANCE CHECK LIST Intervals (Month) 3 6 1 Hydraulic Check the hydraulic cylinder(s), piston for damage noise and leakage • Check the hydraulic joints and hose for damage and leakage • Inspect the hydraulic oil level, refill if necessary •...
Page 32 31 Check the main power cable for damages • 32 Check the start-up protection during charging • Function 33 Check the horn function • 34 Check the air gap of the electromagnetic brake • 35 Test the emergency braking • 36 Test the reverse and regenerative braking •...
Page 33 Waste material like oil, used batteries or other must be probably disposed and recycled according to the national regulations and if necessary brought to a recycling company. The oil level height shall be in the not lifted position min. 0.6L to 0.8L. If necessary add oil at the filling point.
Page 34 e. Wheel replacement procedure Drive wheel Lift the truck with help of hydraulic jack Unscrew five nuts holding the tyre Remove the tire Assemble back with reversed order Torque for nuts 90Nm...
Page 35 Rollers Remove pins pos. 4 Remove axles pos. 12 Remove rollers pos. 11 Assemble in the reversed order Support wheel Remove nut pos. 21 Remove bolt pos. 11 Replace wheel pos. 16 with bearings pos. 15 Assemble in the reversed order Sleeve pos.
Page 36 11. TROUBLE SHOOTING • If the truck has malfunctions follow the instructions, mentioned in chapter 6. Table 5: Trouble shooting TROUBLE CAUSE REPAIR Load weight too high Lift only the max. capacity, mentioned on the ID-plate Battery discharged Charge the battery Lifting fuse faulty Check and eventually replace the lifting fuse Load can’t be...
Page 37 12. WIRING/ CIRCUIT DIAGRAM a. Electrical circuit diagram FU 1 : 10A FU 2：1.5A FU 3：0.5A FU01: 150A FU02: 80A FU03: 30A Fig. 23: Electric diagram EPS（CE）...
Page 38 Table 6: Description of electrical diagram Code Item Code Item Battery Micro switch DC switch Electromagnetic valve Fuse 10A Inter-lock switch Fuse 1.5A Button switch Fuse 0.5A Horn FU01 Fuse 150A Inter-lock switch 1 FU02 Fuse 80A Inter-lock switch 2 FU03 Fuse 30A Inter-lock switch 3...
Page 39 Hydraulic circuit Lifting cylinder Lowering valve Pressure control valve Throttle valve Hydraulic power unit Oil tank Fig. 24: 20EPR-X Hydraulic circuit Lifting cylinder Lowering valve Throttle valve Pressure control valve Hydraulic power unit Oil tank Fig. 25: 25EPR-X Hydraulic circuit...

This manual is also suitable for:

25epr-x