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16EP-X / 20EP-X / 25EP-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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Table of Contents
Related Manuals for Hyundai 16EP-X
Summary of Contents for Hyundai 16EP-X
- Page 1 16EP-X / 20EP-X / 25EP-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.
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Page 3: Table Of Contents
TABLE OF CONTENTS CORRECT APPLICATION ......................... 4 DESCRIPTION OF THE PALLET TRUCK ..................5 Overview of the main components....................5 Main technical data ......................... 5 Description of the safety devices and warning labels (Europe and other, excepting USA) ... 7 Identification plate ........................... - Page 4 11. DECLARATION OF CONFORMITY(valid, if sold within the EU) ............. 39...
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Page 5: Correct Application
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: Description Of The Pallet Truck
2. DESCRIPTION OF THE PALLET TRUCK Overview of the main components Fig. 1: Overview main components Electrical box cover Key switch Battery discharge Indicator Fork chassis Tiller 10. Load wheels Accelerator 11. Drive wheel Safety (belly) button 12. Castors Instrument board cover 13. -
Page 7: Main Technical Data
Main technical data Fig. 2: Technical data 16/20EP-X Fig. 3: Technical data 25EP-X... - Page 8 Table 1: Main technical data for standard version Type sheet for industrial truck acc. to VDI 2198 Manufacturer`s type designation 16EP-X 20EP-X 25EP-X Power(Battery,Diesel,Petrol gas, Manual) Battery Operator type Pedestrian Load Capacity (upper and lower pallets) Q (t) Load center distance...
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Page 9: Description Of The Safety Devices And Warning Labels (Europe And Other, Excepting Usa)
Description of the safety devices and warning labels Fig. 4: Safety and warning labels 16/20EP-X Fig. 5: Safety and warning labels 25EP-X... -
Page 10: Identification Plate
Sticker to read and follow this instruction “No passengers” decal Capacity sticker Crane hook label Identification plate (ID-plate) Sign oil filling point The truck is equipped with an emergency switch (7) which stops all lifting-, lowering-, driving- functions and engages the failsafe electromagnetic brake when it is pushed. The truck is equipped with a safety (belly) button (5) which switches the driving function away from the operator, if the truck travels towards the operator and the tiller is activated in the tillers operating zone. -
Page 11: Warnings, Residual Risk And Safety Instructions
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: Commissioning, Transporting, Decommissioning
4. TCOMMISSIONING, TRANSPORTING, DECOMMISSIONING Commissioning Table 2: Commissioning data Type 16EP-X 20EP-X 25EP-X Commissioning weight [kg] Dimensions 1385x729x1670 1385x729x1735 1385X729X1950 [mm] After receiving our new pallet truck or for re-commissioning you have to do following before (firstly) operating the truck: Check if are all parts included and not damaged •... -
Page 13: Decommissioning
Decommissioning For storage, remove the load, lower the truck to the lowest position, grease all in this handbook mentioned greasing points (regular inspection), eventually protect the truck against corrosion and dust. Remove the batteries and jack the truck safely, so that there will be no flattening after storage. For final decommissioning hand the truck to a designated recycling company. -
Page 14: Lifting
Lifting DO NOT OVERLOAD THE TRUCK! THE MAXIMUM CAPACITY IS 1600kg(16EP-X） ， 2000kg(20EP-X)，2500kg.(25EP-X) Travel with the lowered forks fully underneath the pallet until the load and press the lifting button (15) until you reached the desired lifting height. Lowering Press the lowering button (15) carefully. -
Page 15: Steering
Control the travelling speed by moving the accelerator button (4) carefully until you reached the desired speed. If you move the accelerator button back to the neutral position, the controller decelerates the truck until the truck stops. If the truck stopped, the parking brake will be engaged. Drive carefully the truck to the destination. -
Page 16: Battery Charging And Replacement
The battery weights can be taken from the battery data plate. Manufacturer`s Battery type Capacity Weight Max. dimensions type designation 24 V battery 2PzB-160Ah 155kg 624x146x590mm 16EP-X 24 V battery Li-Ion 100Ah 55kg 624x146x590mm 24 V battery 2PzS-210Ah 195kg 624x212x627mm 20EP-X 24 V battery Li-Ion... -
Page 17: Replacement
Replacement 16EP-X / 20EP-X Park the truck securely and switch off the truck with the key switch (8), push the emergency button (7). Open the battery cover and let it stay upright, disconnect the battery plug (16), then move the battery out with a crane. -
Page 18: Charging
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. Each is represented by a rectangle that corresponds to 10% of the battery charge. Monkey Wrench Symbol It displays the current fault code (TRA is for drive controller failure, STR is for steering controller failure). -
Page 19: Charger Specification
Charger specification Charger Manufacturer`s type Battery type Capacity specification designation 24 V battery 2PzB-160Ah 24V /SN25A 16EP-X 24 V battery Li-Ion 100Ah 24V60A 24 V battery 2PzS-210Ah 24V /SN35A 20EP-X 24 V battery Li-Ion 150Ah 24V60A... -
Page 20: Battery Decals
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 21: Safety Instructions, Warning Indications And Other Notes
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 22: Potential Hazards
condition causing reduction of battery lifetime, the BMS has a protection function that prohibits 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. - Page 23 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 24 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 25 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.
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Page 26: Shipping Information
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 27: Regular Maintenance
8. REGULAR MAINTENANCE Only qualified and trained personnel are allowed to do maintenance on this truck. • • Before maintaining, remove the load from the forks and lower the forks to the lowest position. • If you need to lift the truck, follow chapter 4b by using designated lashing or jacking equipment. - Page 28 18 Check the electric drive motor for noise and damages • 19 Test the display • 20 Check, if correct fuses are used • 21 Test the warning signal • 22 Check the contactor(s) • 23 Check the frame leakage (insulation test) •...
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Page 29: Lubricating Points
Lubricating points Lubricate the marked points according to the maintenance checklist. The required grease specification is: DIN 51825, standard grease. Fig. 18: Lubricating point s Steering castor bearing Support castor bearing Pump Axle Joint Load roller bearing Check and refill hydraulic oil The required hydraulic fluid- type is H-LP 46, DIN 51524 •... -
Page 30: Checking Electrical Fuses
Checking electrical fuses Fig. 20: Location fuses（16EP-X / 20EP-X / 25EP-XL） （CURTIS） Rate 0.5 A 10 A FU01 FU02 150A Table 5: Size fuses（16EP-X / 20EP-X / 25EP-XL） （CURTIS）... -
Page 31: Wheel Replacement Procedure
Wheel replacement procedure Drive wheel Lift the truck with help of hydraulic jack Unscrew five nuts holding the tire Remove the tire Assemble back with reversed order Torque for nuts 90Nm... -
Page 32: Energizing Of Energy Stored Components
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 33: Trouble Shooting
9. TROUBLE SHOOTING • If the truck has malfunctions follow the instructions, mentioned under chapter 6. Table 6: 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 Load can’t be lifted... -
Page 34: Wiring/ Circuit Diagram
WIRING / CIRCUIT DIAGRAM Electrical circuit diagram Fig. 22: Electrical diagram (16EP-X / 20EP-X / 25EP-X) FU01: 150A FU02: 80A FU1: 10A... - Page 35 Table 8: Description of electrical diagram Code Item Code Item Li battery Relay Emergency button Proximity switch Controller Indicator Main contactor Tiller FU01 Fuse 150A Capacitor FU02 Fuse 80A Horn Fuse 10A Micro switch Key switch Electromagnetic valve Lifting contactor Traction motor Steering Controller Electromagnetic brake...
- Page 36 FU01: 150A FU02: 80A FU1: 10A FU2: 0.5A Fig. 23: Electrical diagram ( CE)
- Page 37 Code Item Code Item Battery Relay Emergency button Proximity switch Controller Indicator Main contactor Tiller FU01 Fuse 80A Capacitor FU02 Fuse 150A Horn Fuse 10A Micro switch Key switch Electromagnetic valve Lifting contactor Traction motor Steering Controller Electromagnetic brake Pump motor Diode Table 9: Description of electrical diagram...
- Page 38 FU01: 150A FU02: 80A FU1: 10A FU2: 0.5A Fig. 24: Electrical diagram (Li)( CE) FU3: 1.5A...
- Page 39 Code Item Code Item Li battery Relay Emergency button Proximity switch Controller Indicator Main contactor Tiller FU01 Fuse 80A Capacitor FU02 Fuse 150A Horn Fuse 10A Micro switch Key switch Electromagnetic valve Lifting contactor Traction motor Steering Controller Electromagnetic brake Pump motor Diode Table 10: Description of electrical diagram...
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Page 40: Hydraulic Circuit
Lift cylinder Lowering valve Pressure valve Throttle valve Hydraulic power pack (motor and pump) Oil tank Fig. 25: 16EP-X / 20EP-X Hydraulic circuit Lift cylinder Lowering valve Throttle valve Pressure valve Hydraulic power pack Oil tank Fig. 26: 25EP-X Hydraulic circuit... - Page 41 CE-DD-002 11. DECLARATION OF CONFORMITY(valid, if sold within the EU) [GB] Original CE Declaration of conformity The signatory hereby declares that the specified machine conforms to the EC Directive 2006/42/EC (Machine Directive), and 2014/30/EU (Electro-Magnetic Compatibility, EMC) including their amendments as translated into national legislation of the member countries. The signatory is individually authorized to compile the technical documents and declares that the following standards, including the normative procedures contained therein, have been applied: [D] Original EG- Konformitätserklärung Der Unterzeichner erklärt hiermit, dass die angegebene Maschine den EG-Richtlinien 2006/42/EG (Maschinenrichtlinie) und 2014/30/EU (Elektromagnetische...
- Page 42 [PL] Oryginalny DEKLARACJA ZGODNOŚCI WE Sygnatariusz niniejszym oświadcza, że określona maszyna jest zgodna z dyrektywą WE 2006/42/WE (dyrektywa maszynowa) i 2014/30/UE (kompatybilność elektromagnetyczna, EMC) wraz z ich poprawkami w tłumaczeniu na ustawodawstwo krajowe krajów członkowskich. Sygnatariusz jest indywidualnie upoważniony do sporządzania dokumentacji technicznej i oświadcza, że zastosowano następujące normy, w tym zawarte w nich procedury normatywne: [RO] Original DECLARAŢIE DE CONFORMITATE CE Semnatarul declară...
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