Hyundai 12EPML User manual

12EPML Electric Pallet Truck
(Lithium battery)
Operation Manual
HYUNDAI CONSTRUCTION EQUIPMENT

Welcome to use “HYUNDAI” Electric pallet stacker!
We hope our Electric pallet truck will provide great
convenience for your work！
Please read the manual carefully before operation
This manual is universal manual. We reserve the right to modify technology of
the electric stacker. If there is anything in the manual that is not consistent
with the actual stacker, the actual stacker should be considered correct and the
manual is only for reference.
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Content
1. Safety regulations………………………………………………………………1
2. Description………………………………………………………………………..3
3. Operation…………………………………………………………………………5
4. Operation, maintenance and charging of battery………….…….…7
5. Maintenance………………………………………………………………………9
6. Common faults and Trouble shooting……………………………….….10
7. Treatment of abandoned material………………………………………..11
8. Electrical schematic diagram…………………………………………12
9. Packing list……..………………………………………………………….13

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1. Safety regulations
When operating the truck, one should always wear safe shoes.
When assembling or disassembling the truck, in order to avoid injury, one should
always wear safety goggles.
Attention！
When the truck is damaged or failure-affecting safety occurs, do not go on
operating the truck.
Attention！
The designed truck can only be used on hard and smooth ground.
In the following environmental situations, it is not allowed to operate the truck:
- The air contains dust or gas, which may be able to cause fire or explosion.
- In refrigerating warehouse or some low temperature, salt containing or other
corrosive environments.
- Raining outdoor environment
- Operation on granule or grassland
Attention！
- When operating the truck, careful judgement should be conducted and one
should operate in a responsible manner.
- One should not operate the truck with hand or shoes with oil.
- The operator must not wear loose clothes or jewelry.。
Attention！
- When operating the truck, it should be ensured that the ground possess
sufficient load bearing capacity and the load here refers to the sum of the weight
of the truck and the weight of the goods.
- When there is a protruding object on the truck or around it, which may cause
human injury or forklift damage, one must be very careful.
-- It is strictly prohibited for people to appear around the truck operation
area, which may cause human injury, for example, when goods fall down.
Be careful!
When handling goods on a slope, the operator must be very careful in
operation. The operator should operator in the upper part of the slope as
shown in the figure above.

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Warning！
- When turning, high-speed operation should be avoided to prevent the truck from
turning upside down.
- The goods should not be piled too high to avoid blocking the vision line.
- Braking should be conducted slightly and very carefully to prevent the goods from
sliding off the tray, which may damage the goods.
- It is not allowed for the truck to turn on a slope.
- Before pushing the truck into an elevator, the operator must ensure that the
elevator is able to bear the total weight of the truck and the goods, the total weight
of the operator and other people in the elevator. When entering the elevator, make
sure that the goods enter first and then the operator. When the truck and goods
enter or leave the elevator, other people must not stay in the elevator.
Be careful！
- The load weight should not exceed the truck’s rated load.
- When piling goods, the goods must not be piled too high to avoid goods fall down
or truck turn over when handling.
- It is strictly prohibited to use this truck to transport human being.
- No other people should stay around the truck operation area to avoid injuries and
deaths when the truck suddenly fails in operation.
- When operating the lever or pushing the truck, one must make sure the hand is
put above the lever.
Attention!
- When parking the truck, the forks should be lowered to the minimum height.
- It is not allowed to park the truck on a slope.
- It is not allowed to park the truck in emergency passageway.
- It is not allowed to park the truck in a place blocking traffic or affecting
operation.
- It is not allowed to operate the truck in a raining environment.
- When nobody takes care of the truck, please turn off the general power supply.

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2. Description
This truck is suitable to operate on indoor hard and smooth ground. It is not allowed to operate
the truck for unsuitable applications.
-The ambient air temperature does not exceed +40℃or below -10℃；
-Hard、flat ground；
-Forbid to use this truck in the flammable and explosive or acid-base and other
corrosive environment；
-The loaded Max.gradeability is 3%；
Fig.1

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Model 12EPML
Drive type Electric
Operation type Walkie
Rated load Q(kg) 1200
Load center distance C（mm）600
Height fork lowered h13(mm) 80
Thread Y(mm) 1269/1339
Wheel PU
Wheel dimension，front mm Φ250
Wheel dimension，rear mm Φ80
Wheel number, front/rear （x = driving
wheel）1X-2/4
Lift height h3(mm) 110
Min./Max. height of operation handle in
the driving position h14(mm) 635/1200
Overall length l1(mm) 1623/1693
Length of fork face l2(mm) 501
Overall width b1(mm) 550/680
Fork dimension s/e/l(mm) 45/160/1150(1220)
Fork width b5(mm) 550/685
Wheelbase ground distance h1(mm) 35
Aisle width for pallet 1000x1200 crosswise Ast(mm) 2226/2294
Aisle width for pallet 800x1200 lengthwise Ast(mm) 2095/2132
Turning radius
Wa(mm) 1424/1494
Traveling speed, laden / unladen Km/h 4.8/5
Max. gradeability, laden/unladen % 5/20
Driving motor power KW 0.65
Lifting motor power KW 0.8
Battery voltage/rated capacity V/Ah 48/20
Battery type Lithium
Service weight (with battery) Kg 135
Traveling brake electric
Noise level at operator’s ear, according to
DIN12053 dB(A) 70

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3. Operation
Energization
-Connect the interface of lithium battery.
Fig.2
-Turn on the electric switch.
Fig.3
Lifting and lowering
-Lifting：press the lifting button on the handle.
-Lowering：Hold the knob tightly to lower.
Fig.4
The connectors are connected with
each other.
Turn on the electric
switch with keys.
Lift
Lowering knob

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Travelling
-Turn the handle to travelling scope；
A and C is braking；
B is travelling；
Fig.5
-Rotate the accelerator to start the truck slowly，（For safety, forbid the abrupt acceleration）
Fig.6
Braking
-Release the accelerator when travelling normally, the truck stop slowly by the regenerative
brake of the motor until the brake lock the wheels.
-Turn the handle to A or C quickly when emergency braking, then the brake lock the wheel
to achieve the emergency braking.
Emergency reversing
-The red button at the end of the handle is the emergency reversing button, the truck will
stop immediately and move backwards for a distance when the body touch the emergency
reversing button. It is a safety button which avoids the extrusion of the truck to protect the
operator from injured when he meets the obstacles.
Reverse Forward

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Parking
-Release Speed button to stop running. the truck will slow down until the brake suction
together in the truck .
-Lower the fork to the lowered position .
-Close the electric switch.
-Disconnect the battery wire off the truck if park for a long time.
-
4. Operation, maintenance and charging of the battery
4.1 Battery type and use precautions
5.1.1Battery type：Lithium battery；battery voltage 48V；environmental protection battery，
no Hg and Cd etc.
5.1.2 Precautions
A) Use ambient temperature of battery is -10 ~ 45
B) Charge and discharge every 3 months during the battery stored for a long time
C) Use the battery for the first time before using a new battery, or if it is stored for long periods
of time, fully charge the battery before use
D) Do not short circuit the battery, which may permanently damage the battery
E) Do not burn or destroy the battery, which may cause toxic gases to release or explode
F) Do not weld the battery directly
G) Do not let the battery in an unfavorable environment, such as extreme temperature, deep
cycle, or often overcharge / over discharge
H) If the battery is hot, do not touch until it cools down
Emergency reverse button
Disconnect the battery wire off the
truck if park for a long time.

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I) When removing the battery , grasp the plug by hand instead of stay wire
J) After the battery is used, if the battery is hot and recharging it, cool it in a ventilated
environment
K) Do not put the battery in water or seawater
L) Do not try to separate, squeeze, hit the battery, the battery will heat or fire. Batteries lye is
harmful to the skin and eyes, and will damage the clothes
M) Keep the battery away from the child and contact the doctor immediately if it is found to be
swallowed.
4.2 Quick replacement of the battery
Step I：turn off the electric switch
Step II：Pull the puller of the battery connector, unplug the battery connector.（Note：must
hold the puller when umplug the battery connector, not allow unplug the wire directly）
Step III：hold the battery puller，unplug the battery off the truck.
Step IV：Install the new battery, insert it into the mounting groove.

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Step V：insert the battery connector.
4.3 Precautions of battery charging
a) Must use the special Li-ion charger of our company；working voltage of charger 48V，
Max.charging voltage 54.6V，Charging current 6-7A
b) Do not reverse charge the battery
c) Stop charging immediately if found the battery hot during charging, recharge after
cooling down naturally
d) must hold the puller when umplug the battery connector, not allow unplug the wire
directly
4.4 Power display
5. Maintenance
If the truck is able to operate satisfactorily depends on careful maintenance.
When maintenance is neglected, human safety may be endangered and property may be
damaged. When the truck is in operation, routine inspection should be conducted frequently
and abnormal should be removed in time. Do not operate truck with trouble to ensure safety
and prolong the service life of the truck.
Maintenance: The maintenance of the truck is usually divided into three levels, routine
maintenance, level 1 maintenance and level 2 maintenance.
Red
lamp Yellow
lamp Green
lamp
Green lamp always on：70%-100%
Yellow lamp always on：40%-70%
Red lamp always on：10%-40%
Red lamp flashes：Empty
When the red lamp is on, please prepare to drive the truck to
charge; red lamp flashes as a warning, prompting the truck is
about to stop working, please immediately charge the battery.
If continue to use, lithium battery interior will carry out the
power disconnect protection, then it will not be able to travel.

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Routine maintenance: Once everyday and the main content is to keep the surface clean
and examine if the power supply cable is damaged.
Level 1 maintenance: Once every week. The maintenance contents, besides the contents
of routine maintenance, should focus on if the operation of the components is normal, if
the fastening items are loose, if there is any oil leakage, if there is any abnormal wearing
in mechanical components, if there are abnormal temperature rise or sparks in electric
equipment, etc. Adjustment and trouble shooting should be conducted if any abnormal
situation is discovered.
Level 2 maintenance: It should be conducted periodically and overall inspection should be
conducted according to following requirements:
a. Mechanical maintenance should be conducted every half a year. The main contents are
to replace lubricating oil for the transmission gear and bearing of the drive wheel, apply
lubricant to various rotating joints, while examining if the fastening items are loose, if
the wheels are rotating flexibly, if the fork rises and declines normally. The operation
noise of the truck after maintenance should be no greater than 70db.
b. Maintenance of hydraulic system: Once every 12 months. Examine if the oil cylinders
are in normal state, if there is any internal or external leakage and if the hydraulic oil is
clean. The hydraulic oil is usually replaced every 12 months. ISO oil standard is applied
to hydraulic oil. When the ambient temperature is -5 ~ 40 , HL℃-N32 is adopted and
when the ambient temperature is -35 ~ -5 , HV℃-N20 low temperature hydraulic oil is
used. The waste oil from the replacement should be treated according to the relevant
local regulation and law. Examine if the operation of the load limit valve is normal.
c. Electric equipment maintenance: It should be conducted every three months to examine
if the connectors of electric equipments are reliable, if the switches are normal and if the
insulation of the electric equipment is in normal condition （The insulation resistance of
electric equipment and the truck body should be greater than 0.5MΩ.
6. Common faults and trouble shooting
The table below provides some common failures of the truck in operation and the trouble
shooting：
No. Faults Analysis of cause Trouble shooting
1 Hydraulic oil
leakage
1. Failed oil seal
2. slight damage or wear
on the surface of one or
two components
3. Loose connection
1. Replace the oil seal
2. Replace the damaged
components
3. Re-tighten the
connection
2 Fork does not lift
1. Too great viscosity of
hydraulic oil or
hydraulic oil has not
been injected.
2. Foreign matters in the
oil.
3. The hydraulic power
unit is damaged.
1. Replace hydraulic oil
2. Remove the foreign
matter in oil or replace
hydraulic oil
3. Replace the hydraulic
power unit

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3 Fork does not lower 1. Manual lowering valve
is not adjusted well；
1. Adjust the position of
lowering valve screw；
4 The motor is unable
to operate
1. Power supply switch
has not been turned on
2. Battery has completely
discharged
3. Brake has not been
released
4. Burnt fuse
1. Insert key and turn on
power supply
2. Charging
3. Examine the stroke
switch on the lever if it is
pressed because of
collision and if the braking
switch has been reset.
4. Replace the fuse
5 The charger is
unable to charge Damaged charger Replace the charger
7．Treatment of abandoned materials
The abandoned batteries and hydraulic oil should not be placed carelessly and must be
treated according to the relevant local regulations and laws. Attention must be paid to
environmental protection.

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8. Electrical schematic diagram

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9. Packing list
Packing list of 12EPML Electric pallet truck
(Lithium battery)
Consignee: Ex-work No.:
Contract No.: Ex-work Date：
No. Name Q’ty Net weight
(kg)
Dimension
（L×W×H）
Remarks
1 12EPML Electric pallet
truck 1 A complete set
2 Accessory box 1 Technical documents,
accessories and spare parts.
Note：1．The following documents are in the file bag:
①Operation manual of 12EPML Electric Pallet truck 1 volume
② 12EPML parts catalogue 1 volume
③Qualification certificate 1 copy
④packing list 1 copy
2．Accessories and spare parts
No. Name Application
Type &
specification Q’ty Remarks
1 Key to electric switch Unlock the
electric switch
2
2 Charger Lithium battery
charging
1
3 Fuse 5A Electrical System 1
4 Dust ring Oil cylinder DHS40 1
5 Seal ring Oil cylinder UHS40 1
6 O-ring Oil cylinder 40 x 3.55 1
7 O-ring Oil cylinder 67 x 3.55 1
8 O-ring Oil cylinder 46.2 x 2.65 1
9 Harness Wiring harness
connection
3 x 150 1
10 Fixed button Fix the wiring
harness
ACC-2-B 1
11 Screw Fix the airing
harness
M4 X 6 1