Hyundai 18EP User manual

Operator & Service Manual
Parts Manual

We hope our electric pallet truck will provide great
convenience for your work！
 Please read the manual carefully before operation.
 This manual is a common manual. We reserve the right to modify technology of
the electric pallet truck. If there is anything in the manual that is not consistent
with the actual truck, the actual truck should be considered correct and the
manual is only for reference.
 The instruction manual shall be accompanied with in case of truck leasing or
transfer.
 Please come into contact with our sales department in case of any problem.
Description of symbol：Regulations of the following symbols are of great importance to your safety and
others as well.
Warning!
 Operators must strictly conform to ISO3691“Safety Specifications of Motor Industrial
Vehicles”. Untrained personnel are not allowed to operate the truck.
Danger
Indicates an impending danger. Deaths or severe injuries would be
resulted without any precaution or avoidance. You must observe
those requirements.
Warning
Indicates a potential danger. Deaths or severe injuries would be
resulted without any precaution or avoidance. You must observe
those requirements.
Caution
Indicates a potential danger. Moderate injuries would be resulted
without any precaution or avoidance. You must observe those
requirements.
Notice You shall pay attention to statements that are in direct or indirect
relation with personal security and truck maintenance.

Content
I．Ruled use ..................................................................................................................................... 1
II．Introduction of the forklift ............................................................................................................
1.Use introduction ..................................................................................................................... 2
2.Allowed environment for using .......................................................................................... 2
3.Technical parameter ............................................................................................................... 2
3.1 outline ................................................................................................................................. 2
3.2 main technical parameter(18EP Electric pallet truck) ......................................................... 6
III. Operation introduction ................................................................................................................ 7
1.safety norms...........………………………………………………………………………….7
1.1 safety operation norms ...................................................................................................... 10
1.2 safety drive norms ............................................................................................................. 11
2. drive and operation .............................................................................................................. 12
2.1prepare before operation .................................................................................................... 12
2.2 drive .................................................................................................................................. 13
2.3 important notice after operation ........................................................................................ 15
IV．The usage ,maintenance and charge of the battery ................................................................. 15
1.initial charge ......................................................................................................................... 18
2 usage and maintenance ......................................................................................................... 19
3 storage ................................................................................................................................ 19
4operation of eletrolyte ........................................................................................................... 19
5Operation of storage batteries during the final stage of their lifetime ........................................20
6 emergency treatment ............................................................................................................ 20
7 charger .................................................................................................................................. 20
8. replacement of battery ......................................................................................................... 20
V. Maintenance and repair of the forklift ........................................................................................ 21
1.maintenance of the forklift ................................................................................................... 21
1.1 important notice of maintenance and repair ...................................................................... 22
1.2 before set-up of maintenance and inspection .................................................................... 22
1.3 daily inspection ................................................................................................................. 22
1.4 inspection according to demand ........................................................................................ 23
1.5 different periods of maintenance and inspection ............................................................... 23
1.6 Recommended working medium .......................................................................................... 25
1.7 Structure of lifting cylinder and wearing parts： .............................................................. 2 6
1.8 Maintenance period of consumables and partial parts ........................................................... 26
2. Common faults and trouble shooting ...................................................................................... 27
VI. The Loading and unloading, transportation and store of truck ...................................................... 35
1. The Loading and unloading of truck ....................................................................................... 35
2.The transportation of the truck ............................................................................................. 35

3.The store of truck .................................................................................................................. 35
Appendix I ...................................................................................................................................... 36
Appendix II ..................................................................................................................................... 37
Appendix III .................................................................................................................................... 38

1
I．Ruled use
The truck of the operating instructions is a ground conveying equipment, suitable for lifting
and transporting goods. Must be strictly used, in accordance with the provisions of the
operating instructions within the operation and maintenance of forklifts. The equipment
will be used for any other purpose, are not in conformity with the provisions of the
operation behavior, may lead to injuries and forklift or other property losses. The most
important is to prevent overloading caused by heavy load or to one side. Must comply with
the maximum load limit specified equipment nameplate or load diagram. Not use the
forklift in the fire and explosion hazard area, nor in the prone to corrosion and rust or dust
area.
The user’s obligation and responsibility: In the operating instructions,
"equipment" means any natural or legal persons who directly use or appoint entrust others
to use the forklift. In the rental and other special circumstances, "equipment" is
representative in accordance with the contract terms between equipment owners and
users, assume the obligations of the parties shall operate. Users of the equipment must
ensure forklift used only for specified use, and in a timely manner to eliminate all may
endanger himself or third person’s life and health risk. In addition, equipment users also
must strictly observe the regulations on accident prevention regulations, other security
technology, and equipment operation, maintenance and repair criterion. The equipment
users must ensure that all operators carefully read and fully understand the operating
instructions of the content.
If do not comply with this operation, the company's quality assurance will automatically fail.
Without obtaining the permission of the company customer service department, if the
customer or third party authorization do not regulate the standard operation, the company
will not bear any responsibility for the resulting loss.
The installation of the accessories: The additional equipment installation or
installation, if the forklift affect the functionality or to add, must obtain prior written
approval of the company. In accordance with the actual situation, may also must obtain the
consent of the local department
The audit results of the departments do not represent the company views.

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II. Brief introduction
1. Use instruction
Electric pallet truck is powered by storage battery, and driven by motor. This kind of truck
travels by means of gear drive. The fork is lifted by means of DC motor and hydraulic
transmission, which motivate hydraulic cylinder up and down to lift fork and goods together
2. Allowed environment for using
a. Height above sea level shall not be over 1000m.
b. Ambient temperature shall not be higher than +40℃ and no lower than -25℃.
c. When the ambient temperature reaches +40℃, the relative humidity should not
exceed 50% at a lower temperature, higher relative humidity is allowed.
d. Hard and flat ground.
e. It is prohibited to use the truck in a flammable, explosive or corrosive environment
with acid and alkali.
3. Technical parameters
3.1 Outline drawing

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（1）instrument
This instrument is a combination of battery
capacity indicator, LCD hour meter, fault code
and low-speed indicator, with the battery
capacity indicator of five segments of colorful
LED display. When the storage battery is fully
charged, the five battery capacity indicators
will be green. With battery capacity
consuming up, the five indicators will go out
one by one. When battery discharges by
70% capacity, the last indicator will flicker and shows “energy storage” alarm. When the
battery discharges by 80%, the last indicator becomes red and shows “energy exhaust”.
After the external power supply is cut off, the internal battery can generally keep storage
memory of 10 years. The life service time for monitoring of this instrument is 99999.9
hours recorded on LCD displays. Hour meter resets automatically and continue to time
and display. Only if it is connected to battery, LCD hour meter will start working. This
instrument possesses high reliability under extremely bad environment。
（2）Steering system:
The steering system mainly composes of operation handle, steering device shaft, support
bearings, potentiometer and steering power unit. The system is used to control travel
direction of the truck
（3）Braking:
The traveling brake of this truck is regenerative braking, with parking brake of
electro-magnetic brake. When the accelerator is released during the traveling of the truck,
the controller will carry out regenerative braking at first. This kind of brake can turn the
dynamic energy to electric energy which can be recharged to battery. When the truck is
stopped, the electromagnetic arrester will be out of power and braked again. This type of
No 18EP Name
1 ● Electric controller assembly
2 ●Electric lock
3 ●Instrument
4 ●Emergency power disconnect
5 ●Frei handle
6 ●Hydraulic power unit
7 ●Oil cylinder
8 ●Drive unit
●=standard ○=option
Electricity Quantity
Indicator
Run-Time Display

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regenerative brake with electromagnetic brake not only prolongs the service time of
storage battery but also reduces the wearing of the brake plate, which extends the service
time of brake.
（4）operation controller
1．Horn button 2.lifting button 3.accelerator button 4. Slow-down button
① Lifting and lowering operation: Press the lowering button of the forks, the forks will
descend. While the lifting button is pressed, the fork will rise.
② Accelerator knob: It is used to control the travel direction and speed of the electric truck.
Before operation of the truck, firstly turn the operation handle to area C shown as above. When
the handle is placed in area A, the truck will be powered-off and braked. At this time, the truck
can not drive. When the operation
handle is placed in area C and the
acceleration knob is turned in one
direction, the truck will travel in that
direction. Meanwhile the truck will be
accelerated with the increasing of
rotation amplitude of the knob. When
the accelerator knob is turned in
another direction, the truck will travel
in another direction. Likewise， the
truck will speed up with the increasing
of rotation amplitude of the knob.
③ Horn button： Horn of the truck will
be turned on if you press the button.
④ Slow-down button: When this button is pressed, the truck will travel at an extremely slow

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speed. This button is applicable for operation on especially narrow f ield or on the condition that
the truck needs to be accurately located
（5）Electric lock：It is used to control switching-on and switching-off of main power supply of
the truck. Key of the electric lock shall be kept by the truck driver or personnel who have
been specially assigned. Be sure to cut off the main power supply when you leave the
truck, and take the key of electric lock, for fear occurrence of accident due to operation
carried out by others.
（6）Power switch：It is used to control emergency power-off of the truck. Pulling up the switch,
then main power supply will be cut off, and inserting down represents switching-on. If
your truck were out of control due to some reason, please immediately pull up the switch
to cut off power supply for sake of any occurrence of accident.

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3.2 Main technical parameter (18EP Electric Pallet Truck)

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2. Main technical parameter (Electric Pallet Truck)
Characteristi
cs
1.1 Manufacturer(abbreviated) HHI
1.2 Model 18EP
1.3 Driving model ：Electric(storage battery),
diesel, gasoline, fuel gas electric
1.4 Driving model（Manual, Walking, Stand driving,
Seat driving ,Order picking） walking
1.5 Rated load Q(kg) 1800
1.6 Load center distance c (mm) 600
1.8 Front overhang x (mm) 856
1.9 Tread Y (mm) 1200
Weight
2.1 Service weight(with battery) kg 520
2.2 Axle load, front/rear, laden kg 720/1600
2.3 Axle load, front/rear, unladen kg 420/100
Wheel
chassis
Dimension
3.1 Wheels (rubber, high elasticity, pneumatic tire,
polyurethane wheel) PU wheel
3.2 Wheel dimension, front Φ250×70
3.3 Wheel dimension, rear Φ80×70
3.4 Additional wheel(dimension) Φ114×60
3.5 Wheel number, front/rear（x = driving wheel） 1X+2/4
3.6 Tread, front b
10(mm)
476
3.7 Tread, rear b
11(mm)
400
4.6 Lift height h
5(mm)
120
4.9 Min. /Max. height of operation handle, in
driving position
h
14(mm)
780/1230
4.15 Height, lowered h
13(mm)
84
4.19 Overall length l
1(mm)
1651
4.20 Length to fork face l
2(mm)
500
4.21 Overall width of truck body b
1(mm)
682
4.22 Fork dimension S/e/l(mm) 54×150×1150
4.25 Overall width of fork b
5(mm)
550
4.32 Wheelbase ground distance m
2(mm)
28
4.33 Aisle width, with pallet 1000x1200 crosswise A
st
(mm) 1863
4.34 Aisle width, with pallet 800x1200 lengthwise A
st
(mm) 1913
4.35 Turning radius W
a(mm)
1367
Performance
Data
5.1 Traveling speed, laden/unladen Km/h 6/6
5.2 Lifting speed, laden/unladen m/s 0.06/0.11
5.3 Descending speed, laden/ unladen m/s 0.12/0.13
5.8 Gradeability, laden/unladen % 8/20
5.10 Traveling brake Electromagnetic brake
motor
6.1 Driving motor power kW 1.2
6.2 Lifting motor power kW 1.2
6.4 Battery voltage/rated capacity V/Ah 24/160
6.5 Battery weight Kg 160
Battery dimension（LXWXH） mm 645×148×560
8.4
Noise level at operator’s ear, according to
DIN12053 dB(A) 70

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3.3 Installing position of the warning label and nameplate
No Name Remarks
1 warning label of leg
2 warning label of operation
3 Instructions label of battery
maintenance
4 Nameplate

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III. Operation
Warning
1. Safety Norms
Please pay attention to the following items first before operation of the truck：
1. This electric truck is only limited to utilization indoor with a hard flat floor. Operation in
inflammable, explosive environment or corrosive environment such as acid or alkaline
condition shall be strictly forbidden.
2. Only drivers who have received formal training or are authorized can be allowed to
drive the truck.
3. Read this instruction carefully before operation so as to master the performance of the
truck; check the truck whether it is in its normal condition before each operation. It is
forbidden to use faulty truck; repair by untrained persons is forbidden as well.
4. Overloading operation is forbidden.
5. As for goods carrying and operation, center of gravity of the goods must be within
range of the two forks. It is forbidden to transport loose goods.
6. The truck shall travels slowly when forks pass in or out of pallet.
7. It is strictly forbidden to press the lifting or lowering button during the traveling of the
truck. Meanwhile, don’t switch lifting and lowering buttons rapidly or frequently,
because rapid and frequent lifting or lowering will cause damage to the truck and
goods.
8. Don’t load heavy goods on the forks rapidly！
9. Don’t lay the goods on the truck for a long time！
10. It is strictly forbidden to make sharp turn on narrow aisle. When it is turning, slow
down the truck so as to ensure the safety of personnel and goods.
11. Descend the forks to the lowest position when the truck is not used.
12. It is strictly forbidden to put any part of the body under heavy goods and forks！
13. This truck is suitable to be used on flat ground or flat platform. Don’t put the truck on
the slope for a long time.
14. Overloading operation is forbidden. Otherwise the wheel will skid, resulting in the
damage of wheel and motor as well as danger of the human body and goods.
15. It is strictly to use the truck under stipulated voltage of 20.4V.
16. It is strictly forbidden to conduct charge by connecting the plug to AC power directly.

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1.1 Safety operation norms
（1） Training of driver：
Even though each electric pallet truck may have the same technical parameters, there may
be differences on features of braking and acceleration as well. Never drive the truck until
you get familiar with all those operations.
（2）Wear of the driver during truck driving
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.
（3）Rules that must be observed
Never drive the truck when you are tired or un-concentrated, with an injection of drug, or
after a liquor drinking.
（4）Safety of working place
This kind of electric truck is only limited to utilization indoor with a hard flat floor.
Operation in inflammable, explosive environment or corrosive environment such as acid
or alkaline condition shall be strictly forbidden.
A Good roadway condition shall be kept and the traffic should be smooth.
B Sufficient light ray shall be ensured on working place.
C Fire extinguishing appliances shall be equipped in the places where truck and charging
is operated.
The extinguishing appliances shall comply with the requirements of extinguishing fire of
solid combustible matter and electric apparatus.
D The value of truck noise mentioned in instruction is measured under the condition of
new truck running on flat, smooth and hard ground. If the traffic surface is bad or the
tire of truck is damaged, the noise may be amplified.
（5）Integrity of the truck shall be realized
Warning
Do not remake the truck
A Please observe safety rules and regulations of your working place during operation,
inspection, and maintenance of the truck.
B No modification or addition shall be made to the truck without written permission by
our company. A modification of the truck may have a negative effect on its safe
operation。
（6）Prepare safety operation procedure：Safety operation procedure shall be formulated
with consideration of practical situations before operation of the truck. Safety shall
be taken into full consideration in preparation of the safety operation procedure.
(7）Operation of truck under unsafe condition is strictly forbidden:

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A Operation under unsafe condition is forbidden, such as under conditions with
uneven floor, or impeded road. Goods lifting on slope is strictly forbidden
B Faulty truck is forbidden to use。
C Make sure a daily inspection of the truck would be taken. Please immediately
repair or replace in case of any abnormal conditions.
(8) Overloading operation of truck is forbidden
Warning
Overloading operation of truck is forbidden. Overloading operation would cause
damage to the truck or bring harm to operator
（9）Use suitable pallet
The pallet shall be of suitable dimensions, neither too wide nor too large.
（10）Electrical System Check
Notice
Before checking the electrical system, turn off the key switches and the emergency isolation
switches.
1.2 Safety Operation Specification
（1）Check the safety condition around the truck
A. Before starting up the truck, please ensure that there is no person around it
B. If the driver’s view is shielded by the bulky goods carried, please drive backwards or drive
under the guidance of other working personnel.
C. Ensure no people around the truck when driving backwards
D. Driving through the narrow access shall be guided by working personnel
E. At crossroad or other places impeditive for view, the driver shall not drive until there is no
person at both sides
F. Keep concentration when operating truck.
Warning
Different from the ordinary vehicle, the vehicle driving mechanism is
arranged on the rear car, the car when turning part swing speed is
relatively large, so when the car back close to other objects, we must
slow moving or turning, prevent collision.

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（2）Strictly forbid harsh driving
A. Never start up, brake or turn abruptly.
B. Observe all items of safety rules on working place. Decelerate and sound horn when travel
by other truck or vehicles. Avoid driving in places with bad view.
C. Ensure to provide certain clearance between truck and entrance
(3) Never drive too close to roadside
Ensure to provide enough distance between the truck and roadside or platform edge.
Warning
Avoid turning or loading and unloading operation on slope; otherwise the truck
can go tilting.
Warning
Note that when the car overturned, the driver should rapidly away from the car。
Warning
(4）Forbid deflective transportation.
（5）Passengers on truck must be forbidden.
（6）Never push or pull the handle abruptly
（7）Never use the truck as towing truck.
2. Drive and operation
2.1 Prepare before operation
For the sake of safety operation and good situation of the electric truck, it is
compulsory to check the truck completely before operation. Contact the sales
department of our company when founding problems.
Name No. Check point Check content
Braking
system 1 Operation handle
When the operation handle is turned, with
the handle switching between area A and B,
there is a noise from the brake.

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2 Brake clearance The clearance between brakes should be
kept between 0.2mm and 0.8mm.
Steering
system
3 Operation handle Degree of tightness and rotary flexibility.
4 Oil pipe Leakage or not.
5 Hydraulic oil Appropriate oil quantity.
6 Lifting cylinder Whether there is any oil leakage.
Wheels
7 Pins, screws and all
the fasteners
Check all the fasteners of the truck’s wheels,
i.e. pins or screws, loose or not.
8 Wearing status Compare the parameter list, replace the
wheel when its diameter reduces by 5%.
battery
9 Charge Confirm the display state of the battery
capacity.
10 Electrolyte The solution level and density of electrolyte.
11 Connecting line The connecting line and socket shall be firm.
horn 12 Horn Press down the horn button to check
whether the horn sounds.
instrument 13 Function Turn on the switch of electric lock to check
whether the instrument displays normally.
others
14 Truck frame, etc Damaged or not. If there is any crack.
15 Function
Check that whether lifting, lowering, forward
& backward movement and emergency
reverse of the truck is normal, and if there is
any abnormal noise.
handle
16 Emergency reversing
switch
Put the handle to B section, press the emergency
reversing device, see if the truck can move
forward.
17 Lifting, move button
Check if the lifting, movement of
truck is normal.
Warning Never use the faulty truck
2.2 driving
（1）set-up
Turn the switch of electric lock to ON position. When the operation handle is turned to
area B or area C and accelerator knob is rotated slowly, the truck will start gradually.
The greater the accelerator knob is turned, the faster the truck travels.

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Warning
When forking goods or moving goods, never rotate the accelerator knob rapidly to
speed up the truck abruptly.
（2）Decelerate：
The driving motor of the truck is AC motor. The running speed of motor is controlled by speed
regulation actuator all the time. So, if the accelerator knob is released slowly, the truck will
slow down so as to decelerate.
（3）Turning
The driver stands on the truck pedal in the right gesture and faces the forks. When the truck
travels forward, if the operation handle is rotated counterclockwise, the truck will turn
clockwise. If the operation handle is rotated clockwise, the truck will turn counterclockwise.
When running backward, if the operation handle is rotated clockwise, the truck will turn
clockwise. If the operation handle is rotated counterclockwise, the truck will turn
counterclockwise.
Warning
Different from the ordinary vehicle, the vehicle driving mechanism is arranged on the
rear car, the car when turning part swing speed is relatively large, so when the car
back close to other objects, we must slow moving or turning, prevent collision.
（4）Brake
Release the accelerator knob, can realize brake.
（5）Transportation operation：
The following procedures shall be observed for goods transportation：
 Decelerate when approaching the goods area
 Inspect safety condition around the stacking area
 Adjust position of the truck, placing it in front of place where goods locate
 Slowly start the truck, and insert fork arms to the bottom of goods as deeply as possible
 Press the lifting button, raising forks to a position with a distance of over 40mm between
bottom of the pallet and ground.
6. Start the truck and carry the goods to destination. Press lowering button and put the goods on
the ground, making the forks totally out of the bottom of the pallet. Then backward the truck
slowly.
Notice
Before operating truck, do check the following items: Ensure no goods falling and damaged
in the loading area. Ensure no goods or objects impeditive for safety.

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2.3 Important notice after operation
（1）Parking: Park the truck at appointed place. Never park the truck on slope.
Ensure the following points to be achieved before leaving away the truck.
b. Lay down the fork to the lowest position naturally；
c. Turn the steering wheel to the middle position；
Turn off the key switch
(2）Clean up the truck：
When cleaning up the electrical system, use compressed air but not water.
(3）Charge
Warning
Open flame is forbidden to appear at the charge places, otherwise, explosion or fire
disaster can be caused.(Record of charging condition. Please refer to
the battery charging method operation section).
（4）clean and dry the truck after operation and check the truck as the follows：
a. Keep it all warning signs, nameplate, warnings of the mark complete and clear, the
mark has certain guidance for the operator, reminding and warning function.
b. If there is deformation, distortion, damage or breakage.
c. Add lubricating grease according to the situation.
d. Replace faulty components.

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IV．Usage, maintenance and charge of storage battery
Schematic diagram of charging method
Charging operating method of charger：
1.Pull down the general power switch；
2. Connect the charging plug of storage battery to output connector of charger；
3. Then link the input connector of charger to AC power system；
4. Turn on the charger, and it starts to charge after several seconds.
Warning
Hydrogen is aggregated in the battery box when charging. For this reason, the charging condition shall be
good ventilated. In avoidance of explosion and fire disaster, open flame is forbidden。