Hyundai HYMD500B User manual

Instruction Manual
WARNING: Read the instructions carefully before use.
48V Mini Dumper
HYMD500B

www.hyundaipowerproducts.co.uk
2
Contents
Introduction……..……………………………3
Safety Information…..…………………..4-13
Understand Your Machine.…..…………...4
Personal Safety...…….……………………4-5
Inspect Your Machine…………………......5
Work Area…….……………………………....6
During Use…….………………………………7
When Not in Use……………………………..7
Batteries…….…………………………………8
Charger………………………...……………..8
Electricity…….………………...…………......9
Double Insulated Devices…......…….........9
Vibrations….…………………………..........10
Noise…….……………………………..........10
Residual Risks…………………....................10
Intended Use………………………............11
Personal Protective Equipment…...........12
Symbols On The Machine………………..13
Unboxing…………………………..........14-15
Features………………………….................16
Assembly……..……………………........17-21
Handles………………………………...……17
Front Wheels…………………………...…...18
Rear Axle and Wheels.……………..….…19
Bucket………...……..….……………..….…20
Bucket Guard……….………..………...….21
Battery Charging...………………………..22
Operation……...………………………..23-27
Control Panel……………………….……...23
Pre-Operation Check...…….……….……23
Starting Procedure…….………………....24
Driving……………………………….………25
Load Limits………………………………….26
Unloading…………………………………...27
Stopping…………………………….……….27
Tilt Speed Adjustment…………………….28
Maintenance & Care……………….…29-30
General Maintenance……….………...…29
Cleaning…………………………………….29
Storage……………………………….……...29
Troubleshooting…………………….………30
Technical Data…………...........................31
Recycling And Disposal..………………...32
Declaration Of Conformity…..…………..33
Useful Information…..……………………..34
Our YouTube Channel…..………………..34
Warranty…………………………………….34
Manual Updates….……………………….34
Returning Your Product….……………….34
Leaving A Review….……………………...34
Ordering Spare Parts.……………………..34
Product Record…..………………………...35
Notes……………………………………36-38
Contact Us…..……………………………....39

www.hyundaipowerproducts.co.uk
3
Introduction
Thank You For Purchasing Your HYUNDAI Product
We work very hard to give all of our customers the best possible service. If you
have any problems, before leaving negative feedback, please contact us to give
us a chance to resolve the issue. We would be delighted if you left us positive
feedback! Thank you for purchasing this product.
Important!
This manual has been produced by Hyundai Power Products and should be kept
with the product. Please read and understand these instructions before you use
your product. Failure to do this may result in personal injury or damage to the
product.
The safety precautions and warnings are to ensure your safety and protect you
from harm or damage to the product.
The information contained in this manual was accurate at the time of production,
however HYUNDAI Power Products may make modifications to the product
without notification.
WARNING: READ THE INSTRUCTION BOOKLET THOROUGHLY BEFORE USING
THE MACHINE. Keep for future reference and pass it on if the machine is
loaned or sold to another user.
!

www.hyundaipowerproducts.co.uk
4
Safety Information
Understand Your Machine
• WARNING! You must read these instructions carefully before operating the
machine. Make sure that you are familiar with the controls and properly operate
the machine. You must learn how to stop the machine quickly. If you do not follow
the warnings and instructions, it may result in fire and/or serious injury. Make sure to
save all warnings and instructions for future reference.
• Read this manual and labels affixed to the machine to understand its limitations
and potential hazards.
• Be thoroughly familiar with the controls and their proper operation. Know how to
stop the machine and disengage the controls quickly.
• If the unit is to be used by someone other than original purchaser, or is to be
loaned, rented, or sold, always provide this manual and any needed safety
training before operation. The user can prevent and is responsible for accidents or
injuries that may occur to themselves, to other people, or to property.
• Do not force the machine beyond its limits. Use the correct machine for your
application.
• Know how to stop the machine quickly in case of emergency. Understand the
use of all controls.
• ALL MAINTENANCE other than that listed in this manual, should be carried out by
professionally trained and certified personnel.
• When using this machine for the first time and before actual work, you MUST
learn how to handle the machine from an experienced or skilled person.
Personal Safety
• WARNING! Only competent persons familiar with these instructions should use this
machine. Local regulations can restrict the minimum age of the operator.
• Keep young children, pets, and other people not using the unit away from the
work area. You MUST be in control of your environment and the persons within it.
• Stay alert, watch what you are doing and use common sense when operating
the machine. Never operate the machine when unwell or tired, or if you have
taken alcohol, medicine, drugs or any substances which may compromise
judgment or concentration. A moment of inattention while operating the machine
may result in serious personal injury.
• Appropriate Personal Protective Equipment (PPE), MUST be worn at all times
when operating or repairing the machine.
-Always wear suitable anti-slip and resistant work footwear with hardened toe
protection
- Suitable gloves/Hand Protection
- Suitable Trousers/Leg protection
- Suitable Eye/Face Protection
• Do not wear chains, bracelets or clothing that is loose fitting or hanging ties or
cords. Tie long hair back. Loose clothes, jewellery, or long hair can be caught in
moving parts.
•Always keep hands and feet away from all moving parts during operation.
Moving parts can cut or crush body parts. Always keep hands and feet away from
all pinch points.
!
!

www.hyundaipowerproducts.co.uk
5
Safety Information
Personal Safety (Continued)
• Do not touch parts that might be hot from operation. Allow parts to cool before
attempting to maintain, adjust, or service.
• Do not overreach. Keep proper footing and balance at all times. This enables
better control of the machine in unexpected situations. Extending your body too
far can result in a loss of balance and you may fall which will result in injury.
• Never place any part of your body where it would be in danger if movement
should occur during assembly, installation, and operation, maintenance, repairing
or moving.
• The operator or user is responsible for accidents, hazards or unexpected events
involving the machine that occur whether this is damage/injury to persons or
property. It is the responsibility of the user to carry out suitable risk assessments of
the work area and work carried out . The operator or user must take all necessary
precautions to ensure the safety of themselves and other, especially on slopes or
rough, slippery and unstable ground.
Inspect Your Machine
• Check your machine before starting it. Keep guards in place and in working
order. Make sure all nuts, bolts, etc., are securely tightened.
• You must check the general condition of the machine before use.
• Never operate the machine when it is in need of repair or is in poor mechanical
condition. Replace damaged, missing, or failed parts before using it. Check for
any Hydraulic Fluid leaks and keep the machine in safe working condition.
• Do not use the machine if the machine’s switch does not turn off the machine
when running. Any machine that can’t be controlled with the switch is dangerous
and must be replaced.
• Regularly check to see that keys and adjusting wrenches are removed from the
machine area before starting it. A wrench or a key that is left attached to a
rotating part of the machine may result in personal injury.
• If the machine should start to vibrate abnormally, stop the machine and check
immediately for the cause. Vibration is generally a warning sign of trouble.
• Avoid accidental starting. Be sure the switch is off before transporting the
machine or performing any maintenance or service on the unit. Transporting or
performing maintenance or service on a machine with its switch on invites
accidents.
• Do not tamper with or disable safety systems.
• Only use manufacturer-recommended attachments.
• Before using, always visually inspect to see that the tools are not worn out or
damaged. Replace worn out or damaged elements and bolts in set to preserve
balance.
• Keep the machine in good operating condition. Operating the machine in poor
or questionable condition could result in serious injury.
• Be sure all safety devices are in working order and warning labels are in place.
These items are installed for your safety.
!
!

www.hyundaipowerproducts.co.uk
6
Safety Information
Work Area
• You must only operate the machine in suitable lighting conditions. Daylight or
good artificial light are examples of suitable conditions. Do not use the machines in
low light conditions, at times of heavy fog, or at any other times when your field of
vision might be limited and it would be difficult to gain a clear view of the area.
• Only operate the machines in controlled areas where all persons are aware of
the machine.
• When operating the machine on slopes, always abide by the load limits on Page
26
• Do not work in the rain, when there is a thunderstorm or lightning risk, at times of
strong or gale force winds, or at any other times when the weather conditions
might make it unsafe to use this product.
• Do not operate the machine in excessively wet areas. Liquids spilled on the floor
may result in you slipping.
•DO NOT operate power tools in explosive atmospheres, such as in the presence
of flammable liquids, gases or dust. Power tools may create sparks, which may
ignite the dust or fumes.
!

www.hyundaipowerproducts.co.uk
7
Safety Information
During Use
• Do not operate the machine in confined areas where there may be a risk of
crushing the operator between the machine and another object.
• Never attempt to make any adjustments, while the machine is moving. This
involves changing the speed setting or tilting the bucket.
• WARNING! If something breaks or an accident happens whilst working, you must
turn off the machine immediately and move the machine away to prevent further
damage. If an accident happens with injuries or third parties are injured, carry out
the first aid measures most suitable for the situation immediately and contact the
medical authorities for any necessary health care. Carefully remove any debris
that might cause damage or harm persons or animals should it not be seen.
•Never operate the machine with defective guards or shields, or without safety
devices.
•Never use any defective or damaged power cords or extension lead with this
machine.
You must switch off the machine:
- Before checking or working on the machine.
- When transporting the machine.
- Whenever you leave the machine unattended.
- If the machine starts to vibrate abnormally.
!
When Not in Use
!

www.hyundaipowerproducts.co.uk
8
Safety Information
Batteries
The HYMD500B comes equipped with 4 x 12V Sealed Lead Acid batteries. Batteries
present a risk if they become damaged by the possible leaking of electrolyte.
Electrolyte is an acid and can cause serious burn injuries. Care should be taken
when working on or near them. NOTE: the electrolyte may be in a liquid or gel
form.
Should you come in to contact with electrolyte you should;
• Remove all clothing contaminated with electrolyte. If you cannot remove then
saturate them in water.
• Get medical assistance as soon as possible.
You must advise the medical staff of the type of acid.
• Lead/acid battery = dilute sulphuric acid.
• Nickel/cadmium = potassium hydroxide alkali electrolyte.
• Use fresh running water to wash off excess electrolyte, continue this until medical
assistance arrives. Make sure don’t transfer electrolyte to other body parts.
• If electrolyte comes in to contact with Eyes the electrolyte needs to be
immediately washed away with large amounts of water. Make sure that you do
not wash the electrolyte to another part of your face or body.
• Gasses from charging batteries are highly flammable and great care should be
taken to charge in well ventilated areas.
• There is an explosion risk if the battery terminals are short circuited,
when connecting/disconnecting ALWAYS exercise great care so that
the terminals or battery leads are NOT allowed to touch and cause a
spark. ALWAYS use suitable insulated tools.
The batteries are a very rare and particular specification. As they’re sealed they
are non-serviceable. If you require replacements please contact our parts
department using the information on Page 34 & 39.
!
Battery Charger
!
• ONLY USE THE CHARGER SUPPLIED WITH THE MACHINE. THIS CHARGER HAS BEEN
SPECIFICALLY DESIGNED FOR THIS MACHINE, THIRD PARTY CHARGERS WILL BE
DEEMED DANGEROUS AND UNSUITABLE.
If your charger stops working or becomes damaged you can purchase another
from our parts department. See our Contact Details on Pages 34 & 39
• Do not place any objects on the battery charger and do not place the battery
charger on soft surfaces. There is a risk of explosion.
• If other batteries are used, e.g. imitations, reconditioned batteries or third-party
products, there’s risk of injury as well as damage caused by explosion

www.hyundaipowerproducts.co.uk
9
Safety Information
Double-Insulated Appliances
In a double-insulated appliance, two systems of insulation are provided instead of
grounding. No grounding means that it is already provided on a double-insulated
appliance. Servicing a double-insulated appliance requires extreme care and
knowledge of the system, and should be performed only by qualified service
personnel. Replacement parts for a double-insulated appliance must be identical to the
parts they replace.
!
DANGER : ELECTRICITY CAN KILL –NEVER WORK ON LIVE / ENERGISED EQUIPMENT.
Electricity (Where Applicable)
!
• Prior to carrying out any maintenance work you MUST identify electrical
. isolation methods and isolate all electrical supplies.
• Prior to use and with all electrical supplies isolated, you MUST check all
electrical cables, plugs and connectors for the following;
- Are intact and have no signs of damage, to include but not limited to bare wires,
chaffing, cuts and loose wiring.
- If there are any signs of damage, the damaged item MUST be taken out of service until
the damage has been repaired by an electrically competent person.
- All trailing cables should be routed so as not to cause any kind of trip hazard.
- NEVER work on or near electricity with wet hands, wet clothing and wet gloves.
• The Dumpers plug must match the outlet. Never modify the plug in any way. For
example, never modify the plug to European standard plug to fit a European Standard
Outlet. Always use BS 1363 compatible power outlets.
• DO NOT expose this machine to rain or wet conditions. Water near the batteries or
control systems will increase the risk of electric shock. Never use the cord for carrying,
pulling or unplugging the power tool.
• IMPORTANT: Make sure that the electric circuit is fused, and that the power, voltage and
frequency of the motor is supported by your mains supply. Also, make sure that your power
supply is earthed. Connect your machine to earth. Never open the ON/OFF switchbox.
However, if it should become necessary to do so, contact a qualified electrician. Make
sure that you will never touch live contacts, specifically when you plug or unplug your
machine. This machine and its charger must never get into contact with water.
Using Extension cords for Charging
• To prevent electric shock, use only with an extension cord suitable for outdoor
use. For additional protection, the installation of a residual current device (RCD) having a
rated residual operating current not exceeding 30mA is advisable.
•Before use, check that the extension cord is in good condition. When using an
extension cord, make sure to use one heavy enough to carry the current your product will
draw. An undersized cord will cause a drop in line voltage resulting in loss of power and
overheating.
• Before use, check the supply and extension cord for signs of damage or aging. If the
cord becomes damaged during use, disconnect the cord from the supply immediately. If
the supply cord is damaged, it must be replaced by the manufacturer or a qualified person
in order to avoid a hazard.

www.hyundaipowerproducts.co.uk
10
Safety Information
Vibrations (Where Applicable)
• Prolonged use of hand held (operated) machines will cause the user to feel the effects
of/from vibrations. These vibrations can lead to white finger (Raynaud’s phenomenon) or
carpal tunnel syndrome. This condition reduces the ability of the hand to feel and regulate
temperature, causing numbness and heat sensations and may cause nerve damage and
circulatory tissue death.
• Not all factors that lead to white finger disease are known, but cold weather, smoking
and other diseases that affect blood vessels and blood circulation as well as large and
long-lasting impact of shocks are considered factors in the formation of white finger. Note
the following to reduce the risk of white finger and carpal tunnel syndrome;
• Wear gloves and keep your hands warm.
• Take regular breaks.
• All of the above precautions may help reduce the risk of white finger disease but not rule
out the carpal tunnel syndrome. Long-term and regular users are therefore recommended
to observe the condition of your hands and fingers. Seek medical attention immediately if
any of the above symptoms should occur.
!
Residual Risks
Even when the machine is used as prescribed it is not possible to eliminate all
residual risk factors. The following hazards may arise in connection with operating
the machine in certain work environments:
1. Damage to lungs if an effective dust mask is not worn.
2. Damage to hearing if effective hearing protection is not worn when operating
the machine in areas of excessive noise.
WARNING! This machine produces an electromagnetic field during operation.
This field may under some circumstances interfere with active or passive medical
implants. To reduce the risk of serious or fatal injury, we recommend persons with
medical implants to consult their physician and the medical implant manufacturer
before operating this machine.
!
!

www.hyundaipowerproducts.co.uk
11
Safety Information
Intended Use
The HYMD500B is an Electric Mini Dumper. It is powered by a 1000W 48V HYUNDAI
motor. The 48V Motor is supplied by 4 x 12V 32Ah Sealed Lead Acid Batteries.
This machine is specifically a pedestrian tool, manufactured according to the
latest safety requirements. Every precaution is only effective when it’s followed
exactly.
Being a self propelled machine, only competent operators with a high range of
mobility should use this machine.
Intended Use
This machine is designed and manufactured for transporting loads specified to the
“Load Limits” on page 25.
This machine is intended for use in environments with a maximum ambient
temperature of 32oC. Battery performance will be affected when operating in
environments of excessive heat or cold.
Improper Use
Any other usage not in keeping with the above mentioned ones may be
hazardous and harm persons and/or damage things. Examples of improper use
may include, but are not limited to:
•Using the machine to transport people or animals
•Using the machine as a support or lifting device or any heavy or light objects
•Using the machine to transport any load outside of the specified loads in the
“Load Limits” on page 26.
!

www.hyundaipowerproducts.co.uk
12
Safety Information
Personal Protective Equipment
Appropriate Personal Protective Equipment (PPE), MUST be worn at all times when
operating or repairing the machine. No protective equipment can ensure 100%
protection.
When selecting PPE, make sure it’s CE marked and it suits the user in terms of size,
fit, etc. If more than one item of PPE is worn at the same time, make sure they can
be used together, e.g. wearing safety glasses may disturb the seal of a respirator,
causing air leaks.
!
Hand Protection Must Be Worn
Protective electrically non-conductive gloves are highly
recommended when working.
Foot Protection Must Be Worn
Non-skid heavy duty footwear with toe protection are highly
recommended when working.
Eye/Face Protection Must Be Worn
Always wear safety glasses/goggles and/or face shields. Everyday
eyeglasses have only impact resistant lenses; they are not safety
glasses/goggles.
Protective Clothing Must Be Worn
Do not wear loose clothing, gloves, scarfs, neckties or jewellery (rings,
wrist watches), which can be caught in moving parts.
Head Protection Must Be Worn
Wear a safety helmet with a safety visor.

www.hyundaipowerproducts.co.uk
13
Safety Information
Symbols On The Machine
We have provided safety messages in this manual and on the machine. This
information alerts you to potential hazards that could hurt you or others. Please
read these messages carefully. However, we may not have listed all of the possible
hazards, you must also use your own judgement.
!
Symbol
Description
Symbol
Description
Safety alert –Indicates a
precaution, a warning or
a danger.
Dust mask must be worn
Read operator’s manual. Class II tools symbol.
Hand protection must be
worn
Hearing protection must
be worn
Wheels and Pinch Points
can harm hands and
other body parts.
Eye protection must be
worn
This product complies with
the European directives and
an evaluation method of
conformity for these
directives was done.
This product should not
be disposed of in
domestic waste. Please
contact your local
recycling centre for
disposal service.

www.hyundaipowerproducts.co.uk
14
Unboxing
WARNING : Unboxing and assembling the machine should be done on a flat,
surface with enough room. Disposal of the packaging should be done in
accordance with the local regulations in force.
!
WARNING : Some of the packaging material may be harmful to children. Keep
out of reach of children.
1. Carefully remove the product from the packaging and examine it for any sign of
damage caused during shipping.
2. Lay the contents out and check them. If any part is damaged or missing, you
must not use the machine. Contact HYUNDAI POWER PRODUCTS immediately.
3. You must keep the packaging material in case the machine needs to be
returned or repaired.
4. Ensure that you have all the accessories and tools you need for assembly and
operation including the suitable personal protective equipment.
We recommend that you fill out the information in the ‘Product Record’ section. If
you need to contact an authorised dealer or customer service, you may need to
provide this information.
!

www.hyundaipowerproducts.co.uk
15
Unboxing
*Not To Scale
Feature Descriptions on next page
A
B
C
D
E
F
G
H
I
Bucket Guard
Bucket
Main Body
Left Handle
Right Handle
Wheels
Rear Axle and Wheels
Battery Charger
Manual
A
H
B
E
I
F
G
C
D

www.hyundaipowerproducts.co.uk
16
Features
1
2
3
5
6
7
8
9
1
23
5
6
7
8
9
Bucket –Where the load is carried
Bucket Guard –Protects the user from the bucket tilt.
OPC Lever –Operator Presence Control, engages/disengages drive
Drive Direction Control Switch –Changes drive direction
(Forward & Backward).
Control Panel –Has the Power, Tilt, Speed and Light Switches.
Also the Key and Voltmeter
Rear Wheels –Caster Style wheel for easy manoeuvrability
Battery –48V Battery
Motor –1000W Electric Motor
Front Wheels –These Wheels Drive the machine
4
10
Throttle –A twist throttle that controls the machines acceleration
4
10

www.hyundaipowerproducts.co.uk
17
Assembly
HYMD500B Assembly –Handles
!We Recommend this machine is assembled with 2 people
Install the Left and Right handles as shown in the Diagram below.
Secure with M8 Bolts and Washer. Line up the handles with the holes on
the Main Body
Place a washer on an M8 nut and then secure into the holes.
Complete this on both sides
!Use of Tools will be required during assembly

www.hyundaipowerproducts.co.uk
18
Assembly
HYMD500B Assembly –Front Wheels
Secure the Front wheels using the M14 Nuts provided.
Line up the holes in the Wheels with the threads on the Stub Axle. Place
the wheel on the threads.
Secure the wheel by firstly place a washer and then tightening an M14
on each thread. Repeat on both sides.
Stub Axle

www.hyundaipowerproducts.co.uk
19
Assembly
HYMD500B Assembly –Rear Axle and Wheels
!This step is easier by supporting the main body.
Place the Rear Axle inside the Box section at the rear of the Main Body
Line up the Hole of the Rear Axle with the Hole in the Main Body.
Secure this with the Support Shaft
Then secure the Support Shaft into place with M20 Bolts. Place the
Spring Washers and then Washer on the bolts before securing into the
Main Body

www.hyundaipowerproducts.co.uk
20
Assembly
HYMD500B Assembly –Bucket
The Front of the Bucket is Secured to the Hinge at the Front of the
Machine using the Bolts provided.
Then secure the Tilting Bracket to the Tilting arm that is in the centre of
the Main Body
Tilting Bracket