Hyundai 15EPML User manual

15EPML
Lithium Battery Pallet Truck
 Operation Manual
 Service Manual

Welcome to use “HYUNDAI” Electric Truck!
Wish our electric truck will bring greater
convenience for your work!
 Please read this operation manual carefully before using the truck.
 This operation manual is universal, and we reserve right to make technical
modifications on electric trucks. If this manual does not accord to the actual
truck, please in kind prevail while this manual is only for reference.
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Content
1. Safety regulations ................................................................................... 1
2. Use conditions ......................................................................................... 3
3. Truck parameter ...................................................................................... 3
4. Handle assembly ..................................................................................... 5
5. Truck operation ....................................................................................... 7
6. Use, maintenance and charging of storage battery ............................... 10
7. Keep and maintenance .......................................................................... 13
8. Truck hoisting ....................................................................................... 14
9. Common fault and troubleshooting ...................................................... 15
10. Waste disposal .................................................................................... 16
11. Accessories and spare parts ................................................................ 16
12. Electrical schematic drawing .............................................................. 17
13. Packing list .......................................................................................... 18

1
1. Safety regulations
Always wear safety shoes when using the truck.
In order to prevent injury, always wear protective glasses when assemble or
disassemble the truck.
Caution!
Stop using the truck when it is damaged or faulted.
Attention!
The truck is designed for use on hard and flat ground only.
Never use the truck under the following conditions:
- There is dust or flammable/explosive gas in the air.
- In cold storage, low temperature, salty, or other corrosive environment.
- Outdoor rainy days.
- Operations on grid or grassland.
- Places with gradient greater than the designed grade ability.
Attention!
- When operating the truck, make good judgement with a responsible attitude.
- Never operate the truck with oily hands or shoes.
- Never wear loose clothes or jewelries while operating the truck.
- When operating the truck, make sure the ground has adequate load capacity. Herein
the load capacity refers to the total weight of pallet truck and cargo.
- Be extremely careful if there is any extruding objects on/around the truck
that may cause human injury or damage the truck.
- No person is allowed to appear around the operation area, because it may
injure human body, for example, when cargo falls off.

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Caution!
When transporting cargo on a slope, be extremely careful, and make sure the
operator is operating on the upper end of the slope, as shown in the picture above.
When the truck slides a slope, turn the drive wheels to the biggest angle to prevent
further sliding. This method can only be adopted under emergency.
Warning!
- Avoid fast operations during turning in order to prevent overturn.
- Cargo shall not be too high to block sight.
Brake lightly and cautiously to prevent cargo from falling off.
- Never make turns on a slope.
When pushing the truck into an elevator, make sure the elevator is capable of
bearing total weight of the truck, cargo, operator and other persons in the elevator.
When entering, make sure load enters first, rather than the operator. No person
shall stays in the elevator when load/truck enters/exits the elevator.
Caution!
L - Load weight shall not exceed rated load.
- When stacking, cargo shall not be too high, in order to prevent it from falling off.
- Never transport people by the truck. No person is allowed around the operation
area to prevent human injury caused by truck faults.
-Operator is not allowed to sit or stand on the truck to operate.
Attention!
- Descend forks to the lowest position when parking.
- Never park the truck on a slope.
- Never park the truck at emergency exits.
- Never park the truck at places where it blocks traffic or influences work.
- Never use the truck in rains.
- When nobody guards the truck, turn off power supply.

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2. Use conditions
This truck is designed for use on hard and flat indoor ground. Never use it in a
unsuitable environment.
- Ambient temperature shall be between -10℃and +40℃.
- For hard and flat ground;
- Never use the truck in flammable, explosive or other corrosive environment with
acids or alkali.
- The maximum grade ability is 5%.
3. Truck parameter
Picture 1

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Model 15EPML
Drive type electric
Operation type Walkie
Rated load Q(kg) 1500
Load center C（mm）600
Fork lowest height h13(mm) 80
Tread Y(mm) 1269/1339
Wheel PU
Wheel dimension, front mm Φ210
Wheel dimension, rear mm Φ80
Wheel number (x=drive wheel) 1X-2/2（4）
Lift height h3(mm) 110
Operation handle in driving position, min./max. height h14(mm) 635/1200
Overall length l1(mm) 1623/1693
Length of fork face l2(mm) 473
Truck body width b1(mm) 550/680
Fork dimension s/e/l(mm) 45/160/1150(1220)
Fork outer width b5(mm) 550/685
Wheelbase center ground clearance h1(mm) 35
Aisle width for pallets 1000x1200 crossways Ast(mm) 2226/2294
Aisle width for pallets 800x1200 lengthways Ast(mm) 2095/2132
Turning radius Wa(mm) 1424/1494
Travel speed, laden/unladen Km/h 4.8/5
Max. grade ability, laden/unladen % 5/20
Driving motor power KW 0.65
Lifting motor power KW 0.8
Battery voltage/rated capacity V/Ah 48/20
Travelling brake electric
Noise level at driver’s ear according to DIN12053 dB(A) 70
Weight (including battery) Kg 136

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4. Handle assembly
For safe transportation and packaging, handles of the truck have been disassembled
when ex-factory. Therefore, users should assemble handles before use. The assembly
procedures are as follows:
4.1 Refer to drawing 1, disassemble pin 1 from pin 2, and pull out pin2.
4.2 Refer to drawing 2, take down screw 3 & remove cover plate 4 from handle assembly 5.
4.3 Refer to drawings 3 and 4, insert handle assembly 5 to A, connect handle assembly 5
and pump 10 with pin 2, then make chain 8 go through hole of pin 2. Rotate handle 5 to
horizontal position and pull out pin 9, and keep pin 9 well for next use. Connect wiring harness
in handle assembly 5 and wiring harness on truck body by connector 6, and fasten with belt
to ensure reliable connection (refer to drawing 5). After connecting the wiring harness, fix
wiring harness to handle assembly 5 through line card 7.
Drawing
1 Drawing2
Drawing3 Drawing4

6
Drawing5 Drawing6
4.4 Refer to drawing 4 & 6, hook screw nut on the end of chain 8 into groove of lever
plate 11.
4.5 Finally, fix pin 1 through pin 2, and install cover plate 4 back to handle assembly 5.
Cable Tie
Cable Tie

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5. Truck operation
Truck powering on
- Plug in lithium battery interface.
Drawing 2
- Open lock
Drawing 3
Connector insert
Open lock with key

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Fork lifting/lowering
- Lifting: operate lifting button on operation handle.
- Lowering: hold knob to lower.
Drawing4
Truck travelling
Rotate handle to travelling area
A and C are braking area, B is travelling area.
Drawing 5
- Rotate accelerator slowly to start truck (for safety reasons, fast acceleration is prohibited)
Lifting button
Lowering knob

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Drawing 6
Truck braking
- Release accelerator during normal travelling, and the truck will stop slowly through motor
regenerative braking until brake locks.
- In emergency, rotate operation handle quickly to area A or C (drawing 5), and the brake
will lock to release emergency braking.
Emergency reverse function
- The red button at rear end of handle is the emergency reverse button. When human body
touches the button, the truck will stop travelling forward immediately and will travel
backward for some distance. This safety switch is designed to prevent human damage
caused by truck squeezing when encountering obstacles.
Truck parking
- Release acceleration button to make the truck stop travelling. Then truck will decelerate
slowly until brake closes.
- Descend forks to the lowest position.
- Turn off lock.
- For extended parking, separate power line and truck.
Emergency reverse
Backward Forward

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6. Use, maintenance and charging of storage battery
6.1 Type of storage battery and use precautions
6.1.1 Battery of this truck is lithium-ion battery; battery voltage48V. This is environmentally
friendly battery without mercury or cadmium.
6.1.2 Precautions
a) Use temperature: -10 ~ 45；
b) If the battery is to be placed for a long time, charge and discharge it every three months;
c) Please fully charge the battery before use a new battery or use a battery that has been
stored for a long time;
d) Never short circuit the battery, which may damage it permanently;
e) Never burn or damage the battery, which may cause release of toxic gases or explosion;
f) Never weld the battery directly;
g) Never place the battery in an unfavorable condition, such as extreme temperature, deep
circulation, or frequent overcharging/over-discharging;
h) If the battery becomes too hot, never touch it before it cools down;
i) When remove battery pack, hold the plug rather than the wire;
j) If the battery becomes too hot after use, please cool it down in a well-ventilated
environment before charging again;
k) Do not place the battery in water or sea water;
l) Do not try separating, squeezing or striking the battery, because the battery may become
hot or cause fire. Alkali liquid in battery is harmful to eyes and can damage clothes;
m) Keep battery away from children.
6.2 Quick replacement of battery
Step 1: turn off key
Step 2: hold knob of power supply connector, and pull out power supply connector.
(Attention: you must hold the knob when pull out the connector; never pull wire directly)

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Step 3: hold the battery knob forcefully to pull out the battery from truck.
Step 4: install new battery, insert it into mounting groove.
Step 5: insert power supply connector.

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6.3 Precautions for battery charging
a) You must use our special Li-ion charger; charger working voltage is 48V, the
maximum charge voltage is 54.6V, charge current is 6-7A
b) Do not conduct reverse charging
c) If the battery becomes hot obviously during charging, please stop immediately, and
charge again after is cools down
d) When pulling the charger connector, hold the knob rather than pull the wire directly
6.4 Concerning power indicating
Red
Yellow Green
Green light on: 70%-100%
Yellow light on: 40%-70%
Red light on: 10%-40%
Red light flashes: null
If red light is on, please prepare to charge the truck;
red light flashing is warning that the truck will stop
working and please charge it. If you continue to use it,
lithium battery will be disconnected, and truck will be
unable to travel.

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7. Keep and maintenance
Whether the truck can serve satisfactorily depends on careful maintenance. Neglect of
maintenance may harm human body and damage cargo. Therefore, when you use the truck,
please conduct inspections timely, exclude abnormal phenomenon, and never use a faulted
truck in order to ensure safety and prolong service life.
Maintenance: maintenance of the truck is divided into three levels, i.e. daily maintenance,
first level maintenance and second level maintenance.
Daily maintenance: conducted daily, mainly to keep truck surface clean and check
whether power wire is damaged.
First level maintenance: conducted weekly, mainly to check whether each component
functions normally, whether each fastener is fixed, whether there is leakage, whether the
mechanical part has abnormal wearing and whether the electrical part has abnormal
temperature rise or sparks. For any abnormal phenomena, adjust and exclude timely.
Second level maintenance: conducted periodically, and conduct full inspections for the
following aspects:
a. Mechanical maintenance: conducted half a year, mainly to check whether any fastener
becomes loose, whether each wheel turns flexibly, and whether forks can lift and lower
normally. After maintenance, the running noise shall not exceed 75dB.
b. Hydraulic maintenance: conducted annually, mainly to check whether oil cylinders are
normal, whether there is inner or outer leakage, whether hydraulic oil is clean, and replace
hydraulic oil every 12 months generally. Adopt ISO oil quality for hydraulic oil.
When ambient temperature is -5 ~ 40℃, adopt L-HV32; when ambient temperature is -
10 ~ -5℃, adopt L-HV15 low temperature hydraulic oil. The replaced wasted oil shall be
disposed according to local laws and regulations. Check whether limit valve works normally.
c. Electrical maintenance: conducted every three months, to check whether each joint is
reliable, whether switches are normal, and whether insulation is normal (insulation resistance
between electrical part and truck body shall be greater than 0.5M ).Ω
7.1 Adding hydraulic oil
Find oil adding port

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8. Truck hoisting
Use wrench No. 5 to remove screw at the
adding port. The total required adding
amount is 250ml.
After oil has been added, lift and lower for
2-3 times unladen, lift forks to the
maximum height, then fasten the screw. If
washer at the oil port is damaged, replace
it with a new washer.
Fasten accordingly for hoisting

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9. Common fault and troubleshooting
Some common faults and troubleshooting are listed in the table below:
No. Fault Cause analysis Troubleshooting
1 Hydraulic oil leakage
1． Sealing failure;
2． Some spare parts
have slight damage
or wearing in surface.
3． Loose connection.
1． Replace sealing;
2． Replace damaged parts;
3． Fasten loose points again.
2 Forks not lifting
1． Work oil too
viscous, or work oil
not added;
2． Impurities in oil;
3． Hydraulic power unit
damaged.
1． Replace work oil;
2． Clear impurities in oil line,
replace work oil;
3． Replace hydraulic power
unit.
3 Forks not lowering
1. Manual lowering
valve not properly
adjusted.
1. Adjust lowering valve screw
position.
4 Motor cannot work
1. Power supply not
turned on
2. Battery runs out of
power
3. Brake not released
4. Fuse burnt
1. Insert key and start power
supply
2. Charge
3. Check whether range
switch on handle is pushed
down by collision, and
whether brake is damaged;
4. Replace fuse
5 Charger cannot charge Charger damaged Replace charger

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10．Waste disposal
For waste batteries and hydraulic oil, do not litter around; for environmental considerations,
dispose them according to local laws and regulations.
11. Accessories and spare parts
No. Name Use position Specification Q’ty Remarks
1 Key Open lock 2
2 Charger Lithium battery 1
3 Fuse 10A Electric part 1
4 Dust ring Oil cylinder DHS40 1
5 Seal ring Oil cylinder UHS40 1
6 O-ring Oil cylinder 40X3.55 1
7 O-ring Oil cylinder 67X3.55 1
8 O-ring Oil cylinder 46.2X2.65 1
9 Belt
Handle wiring
harness
connection
3X150 1
10 Belt
Wiring harness
fixing 4X150 2
11 Screw
Wiring harness
fixing M4X6 2

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12. Electrical schematic drawing

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13. Packing list
Packing List of 15EPML Pallet Truck
Consignee: Manufacture No.:
Contract No.: Manufacture date:
No. Cargo Q’ty Net weight (kg) Outline
dimension
(L x W x H)
Remarks
1 15EPML pallet truck 1 Whole truck
2 Accessory bag 1
Technical documents,
accessories and spare
parts within
Note: 1．The following files are included in the technical document bag:
① 15EPML pallet truck Operation Manual 1 volume
② 15EPMLpallettruckPartsCatalogue 1volume
③ CertificateofQuality 1copy
④Packinglist 1copy
2．Accessories and spare parts
No. Name Use position Specification Q’ty Remarks
1 Key Open lock 2
2 Charger Lithium battery 1
3 Fuse 10A Electric part 1
4 Dust ring Oil cylinder DHS40 1
5 Seal ring Oil cylinder UHS40 1
6 O-ring Oil cylinder 40X3.55 1
7 O-ring Oil cylinder 67X3.55 1
8 O-ring Oil cylinder 46.2X2.65 1
9 Belt Handle wiring
harness connection 3X150 1
10 Belt Wiring harness fixing 4X150 2
11 Screw Wiring harness fixing M4X6 2