Hyundai 12EP-XB Operator's Manual
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Hyundai 12EP-XB Operator's Manual

Hyundai 12EP-XB Operator's Manual

Electric pallet truck
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12EP-XB
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 12EP-XB

  • Page 1 12EP-XB 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

    TABLE OF CONTENTS CORRECT APPLICATION ........................ 1 DESCRIPTION OF THE PALLET TRUCK ..................2 Overview of the main components ....................2 Main technical data ........................3 Description of the safety devices and warning labels (Europe and other, excepting USA) ... 5 Identification plate .........................
  • Page 4 Lubricating points ........................28 Check and refill hydraulic oil ......................28 Checking electrical fuses ......................29 TROUBLE SHOOTING ........................30 10. WIRING/ CIRCUIT DIAGRAM ......................31 Electrical circuit diagram ......................31 Hydraulic circuit ........................... 39 Original CE Declaration of conformity ....................40...

  • 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. The trucks are designed to lift, lower and transport palletized loads. A wrong usage can cause human injuries or can damage equipment.

  • Page 6: Description Of The Pallet Truck

    2. DESCRIPTION OF THE PALLET TRUCK a. Overview of the main components Fig. 1: Overview main components Safety (belly) button Fork Tiller Load roller Discharge indicator and charging indicating LED Battery Key switch Apron Emergency button Driving unit Hydraulic unit cover Side roller (option) Chassis...

  • Page 7: Main Technical Data

    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 12EP-XB Manufacturer`s type designation Drive Battery Operator type Pedestrian Load Capacity / rated load Q (t) Load center distance c (mm) Load distance ,center of drive axle to fork...

  • Page 9: Description Of The Safety Devices And Warning Labels (Europe And Other, Excepting Usa)

    Description of the safety devices and warning labels (Europe and other) Fig. 3: Safety and warning labels Sticker to read and follow this instruction Capacity sticker Emergency button sticker Battery ID plate Sign oil filling point No collision sticker Warning sticker Battery warning sticker “No passengers”...

  • Page 10: Identification Plate

    c. Identification plate Model Max Battery weight Type Min. Battery weight Serial Number Voltage / Rated power Load capacity 10 Manufacturing date Lift height Truck weight (without battery) Fig. 4: Identification plate 3. WARNINGS, RESIDUAL RISK AND SAFETY INSTRUCTIONS DO NOT ...

  • Page 11: Commissioning, Transporting, Decommissioning

     To prevent unintended sudden movements when not operating the truck (i.e. from another person, etc.), press emergency switch (5) or remove the key (4). 4. COMMISSIONING, TRANSPORTING, DECOMMISSIONING a. Commissioning Table 2: Commissioning data 12EP-XB 12EP-XB Type (540X1150) (685X1150)

  • Page 12: Decommissioning

    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 13: Operating Instructions

     Check the functions of braking by activation of tiller arm sensor, reversing of driving buttons, release of driving buttons and of the safety (belly) button (section 6f).  Check the function of driving with tiller in its vertical position (section 6d). ...

  • Page 14: Lifting

    b. Lifting DO NOT OVERLOAD THE TRUCK! WHEN THE LOAD CENTER IS 600MM THE MAXIMUM CAPACITY OF 12NEP-XB IS 1200kg. Travel with the lowered forks fully underneath the pallet and press the lifting button (Fig. 7, 16) until you reached the desired lifting height. c.

  • Page 15: Steering

    with the accelerator-button. Press turtle button (Fig.7, 18) to enter into slow speed mode, travel slowly by moving the accelerator button (Fig.7,14), press turtle button again to return back to regular mode. Press turtle button and hold for 2 seconds to activate driving function with tiller in its vertical position when operating in confined areas.

  • Page 16: Battery Safety, Charging And Replacement

    7. BATTERY SAFETY, CHARGING AND REPLACEMENT a. 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.

  • Page 17: Battery Decals

    b. Battery Decals Fig. 10: Battery decals Table 3: Battery Decals Item Description Item Description Disposal mark Warning notice: "Avoid collision” Charging indication Safety information Serial number No random disposal Fuse location Fuse label Identification plate...
  • Page 18 Battery identification plate Fig. 11: Battery identification plate Table 4: Battery data plate Item Description Item Description Manufacturer trademark Battery capacity Battery information Model designation CE mark and other safety labels Voltage range Battery manufacturer Battery weight Manufacturer address Operating temperature range Rated voltage Service mass is indicated on the battery data plate, the center of gravity is located approximately at middle of the battery case...

  • Page 19: Safety Instructions, Warning Indications And Other Notes

    c. 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. Replacement of parts is not assumed. 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 20 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 21 Symbols - Safety and Warnings Table 5: Symbols - Safety and Warnings 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. Avoid fire and short circuits causing overheating.
  • Page 22 Suitable extinguishing agents  Carbon dioxide extinguisher (CO2)  Water (not on mechanically opened or damaged batteries)　 Unsuitable extinguishing agents  Foam  Grease fire extinguishing agents  Powder extinguishers  Metal fire extinguishers (PM 12i extinguishers)  Metal fire powder PL-9/78 (DIN EN 3SP-44/95) ...
  • Page 23 Battery lifetime, maintenance and storage The lithium-ion batteries are maintenance-free. Deep discharge can damage the battery Self-discharge without periodical recharge can lead 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 24 Faults If any damage is found to the battery or battery charger contact the service provider immediately. Do not open the battery or attempt to repair it. Disposal and transport of a lithium-ion battery Instructions for disposal Lithium-ion batteries must be disposed in accordance with the relevant national environmental protection regulations.

  • Page 25: Charging The Battery

    d. Charging the battery Charge Status Indicator Fig.12: Charge Status Indicator The charge status indicator of the battery is integrated in the control handle. The 1st green LED from left is on, indicating 75% -100% of battery power. The 2nd blue LED from left is on, indicating 50% -75% of battery power. The 3rd yellow LED from left is on, indicating 25% -50% of battery power.
  • Page 26 If the green LED does not light up or if the red LED lights up permanently or not at all, this indicates a fault. The truck is equipped with the following batteries: Table 9: Available batteries Model Battery options Weight 5.8 kg 24V20Ah lithium battery 12EP-XB 7.5 kg 24V36Ah lithium battery...
  • Page 27 Charging the battery Fig.13: Charging the battery Requirements  The truck is parked securely.  The battery charger is approved for the battery type in use. Tools and Material Required  Battery charger Procedure  Open the charging socket (21) of the battery and connect the charge connector (22) of the battery charger (20).

  • Page 28: Battery Removal And Installation

    e. Battery removal and installation Fig.14: Removing the battery Removing the battery Requirements  The truck is parked securely.  The emergency disconnect switch is actuated. Procedure ● Unlock the battery latch (23). ● Lift the battery (24) up by the battery handle (10). The battery has been removed.
  • Page 29 Battery installation Fig.15 : Battery Installation Installing the battery Requirements  The truck is parked securely.  The emergency disconnect switch is actuated. Procedure  Insert the battery (38) into the battery compartment.  The plug connection (45) between the battery and truck must be fully connected. ...

  • Page 30: Regular Maintenance

    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 31  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)  24 Check function and mechanical wear of the accelerator ...

  • Page 32: Lubricating Points

    b. Lubricating points Lubricate the marked points according to the maintenance checklist. The required grease specification is: DIN 51825, standard grease. Fig.16: Lubricating point s c. Check and refill hydraulic oil It is recommended to use hydraulic oil in connection with average temperature: Environment temperature –5℃~25℃...

  • Page 33: Checking Electrical Fuses

    Checking electrical fuses Remove the main cover. The fuses are located according to Fig.17; the size is according to table 12. Fig.17: Location of fuses for 12EP-XB Table 12: Size of the fuses Rate FU 1 FU 01...

  • Page 34: Trouble Shooting

    TROUBLE SHOOTING  If the truck has malfunctions follow the instructions, mentioned in chapter 6. Table 13: Trouble shooting TROUBLE CAUSE REPAIR Load weight too high Lift only the max. capacity, mentioned on the ID-plate Battery low power Charge the battery Lifting contactor failure Check and contact with service support for Load can’t be...

  • Page 35: Wiring/ Circuit Diagram

    10. WIRING/ CIRCUIT DIAGRAM a. Electrical circuit diagram 12EP-XB without speed reduction on curves Fig.18: Electric diagram...
  • Page 36 Table 14: Description of electrical diagram Code Item Code Item Battery CAN tiller Controller Proximity switch Pump motor Traction motor Pump contactor Electromagnetic brake Emergency button 10A fuse Electromagnetic valve FU01 70A fuse Micro switch...
  • Page 37 12EP-XB with speed reduction on curves Fig.19: Electric diagram...
  • Page 38 Table 15: Description of electrical diagram Code Item Code Item Battery CAN tiller Controller Proximity switch Pump motor Traction motor Pump contactor Electromagnetic brake Emergency button 10A fuse Electromagnetic valve Proximity switch Micro switch FU01 70A fuse...
  • Page 39 12EP-XB without speed reduction on curves (EN1175-2020) Fig.20: Electric diagram...
  • Page 40 Table 16: Description of electrical diagram Code Item Code Item Battery CAN tiller Controller Proximity switch Pump motor Traction motor Pump contactor Electromagnetic brake Emergency button 10A fuse Electromagnetic valve FU01 70A fuse Micro switch...
  • Page 41 12EP-XB with speed reduction on curves Fig.21: Electric diagram...
  • Page 42 Table 17: Description of electrical diagram Code Item Code Item Battery CAN tiller Controller Proximity switch Pump motor Traction motor Pump contactor Electromagnetic brake Emergency button 10A fuse Electromagnetic valve Proximity switch Micro switch FU01 70A fuse...

  • Page 43: Hydraulic Circuit

    b. Hydraulic circuit Lifting cylinder Lowering valve Throttle valve Pressure control valve Hydraulic power unit Oil tank Fig.22: Hydraulic circuit...

  • Page 44: Original Ce Declaration Of Conformity

    CE-DD-003 Original CE Declaration of conformity [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 45 [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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