Hyundai 20EDPR User manual

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20EDPR
Electric Pallet Truck
Operation Manual
Parts Catalogue

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We hope our electric trucks will bring great
convenience to 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.

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Content
Ⅰ．Specified use ............................................................................................................. 1
Ⅱ．Forklift introduction .................................................................................................... 1
1. range of application................................................................................................ 1
2. service environment ............................................................................................... 1
3. technical parameters .............................................................................................. 1
3.1 structure....................................................................................................... 2
3.2 main technical parameters (20EDPR Electric Pallet Truck) ................................ 2
Ⅲ.Operating instruction ................................................................................................... 7
1.Safety norms……………………………………………………………………………………………..………..9
1.1 safety instructions ......................................................................................... 9
1.2 Safety operation specification…………………………………………………..…………………10
2. Drive and operation.............................................................................................. 11
2.1 inspection before operation ........................................................................ 12
2.2 driving ...................................................................................................... 12
2.3 notice and inspection after operation ......................................................... 17
Ⅳ．Maintenance、charge and replace of battery.............................................................. 17
1. initial charge .................................................................................. ……………………16
2 use and maintenance ........................................................................................... 17
3 storage ............................................................................................................... 18
4 operation of electrolyte.......................................................................................... 18
5 storage battery operation of end service life ........................................................... 18
6.emergency treatment ............................................................................................ 18
7 charger................................................................................................................. 18
8. replacement of battery ......................................................................................... 22
Ⅴ. Maintenance and repair…………………………………………………………………………………………..22
1. Maintenance ........................................................................................................ 23
1.1notice of maintenance .................................................................................. 20
1.2 check and maintenance before use ............................................................. 20
1.3 daily inspection ........................................................................................... 20
1.4 inspection as needed ................................................................................... 21
1.5. inspection and maintenance........................................................................ 21
1.6 working medium recommend ....................................................................... 22
1.7 structure of lift oil cylinder and wearing parts(support leg)：......................... 23
1.8 structure of lift oil cylinder and wearing parts(forks)…………………………………….23
1.9 maintenance period of consumables and partial parts ............................... 23
2. Common faults and trouble shooting ..................................................................... 24
Ⅵ. The store, transportation and loading of truck ........................................................... 29
1. loading and unloading of truck .............................................................................. 29
2. transportation ...................................................................................................... 29
3. storage .............................................................................................................. 29
Appendix I...................................................................................................................... 30
Appendix II .................................................................................................................... 31

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Appendix III ................................................................................................................... 32
Ⅰ．Specified use
the forklift truck is introduced for a ground conveying equipment, suitable for lifting and
transporting goods.
Must be in strict accordance with the provisions of the operating instructions in use, operation
and maintenance of forklift. It is used for any other purpose, which are not in conformity with
the provisions operation behavior, can lead to injuries and fork lift truck or other property
damage. The most important thing is to prevent the load is overweight or swaying caused by
overload. Must abide by the the biggest load limit in equipment nameplate or Load graphic
Drawing can’t use the fork lift truck in a fire and explosion hazard area, cannot use in easy to
cause corrosion rust and dust area.
Obligations and responsibilities of equipment user：“equipment user”Refers to
natural person or legal person who is direct use or appointed entrust others use the forklift in
this operation manual. In the rental, lease and other special circumstances, “equipment user”
represent the contract terms between equipment ower and user. Equipment user must ensure
that the forklift only is used to specified use, and promptly eliminate all may endanger the risk
of life and health to user himself or a third party. In addition, the equipment use party must
strictly abide by the accident prevention regulations, other safety technical regulations, and
equipment operation, maintenance and maintenance philosophy. Equipment user must ensure
that all operations staff carefully read and fully understand the content of the operating
instructions.
If you don't follow the operating instructions, the company's quality assurance to be
automatic failure. If the customer and/or the third party to make the equipment non-standard
without any allowable from out customer service department.，we will not undertake any any
responsibility if there has any lost.
Installation accessories：If impact the function of the forklift truck or have added and need
to install additional device，must obtain the written consent of the company. According to the
actual situation, may also must obtain the consent of the competent department of local.
Examine and verify results of department in charge do not represent the company opinion.

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Ⅱ．Forklift introduction
1. Range of application
20EDPR series electric pallet truck is powered by storage battery, and driven by motor. This kind
of truck travels by means of gear transmission. The fork is lifted by means of DC motor and
hydraulic actuation, which motivate hydraulic cylinder up and down to lift fork and goods
together.
Rated load datails on the forklift nameplate.
2. Service environment
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.
f. Because the vehicle itself without lighting equipment,so the truck should use in light
brightly.
3. Technical parameters
3.1 Structure

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（i）Instrument:
This instrument is a combination of battery
capacity indicator and LCD hour meter, with the
battery indicator of ten segments of colorful LED
display (5 red segments, 3 yellow segments and 2
red LED).When battery discharges by 70% capacity,
one red flicker lamp shows “energy storage” alarm.
When the battery discharges by 80%, two red
flicker lamps show “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, and floating
No.
20EDPR
Name
1
●
Steering mechanism
2
●
Instrument
3
●
Electric lock
4
●
Handle
5
●
Guardrail
6
●
Hydraulic power unit
7
●
Drive unit
8
●
Pedal
9
●
Electric control assembly
10
●
Battery
11
●
Emergency power disconnect
12
●
Mast assembly
13
●
Lift oil cylinder
14
●
Fork carriage assembly
●
●= standard assembly ○=optional
Electricity Quantity Indicator
Run-Time Display

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support bearings. The system is used to control travel direction of the truck.
（3）Braking:
The brake of this truck is electromagnetic. When the accelerator pedal is released, the
electromagnetic arrester will be out of power and braked. When the accelerator is released
during the traveling of the truck, the controller will carry out electric brake at first. This kind of
brake is regenerative braking and 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 electromagnetic brake type not only prolongs the service time of
storage battery and arrester but also reduces the wearing of the brake plate.
（4）Operation control
1．Lift button of support leg 2.Accelerator knob 3.Emergency reverse button 4.Horn
5.Slow button 6.Lift button of fork
①Lifting and lowering operation: Press the lowering button of the forks, the forks will lower.
While the lifting button is pressed, the fork will lift. Press the lowering button of the support leg,
it lowers, Press the lifting button of the support leg, it lifts. Lift the forks when stacking and lift
the support leg when carring.
②Accelerator 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 B shown as above. When
the handle is placed in area A or C, the truck will be powered-off and braked. At this time, the
truck can not drive. When the operation handle is placed in area B 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.
③Horn button：Horn of the truck will be turned on if you press the button.
Emergency reverse button: when the operation handle is placed in area B and the emergency
reverse button is pressed, the truck will travel in an opposite direction away from the operator
immediately. This is a safety switch which can avoid the operator from being squeezed under

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unexpected condition.
④Slow button: When this button is pressed, the truck will travel at an extremely slow speed.
This button is applicable for operation on especially narrow field 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）Battery main switch ：to control the emergency power off,put down the mushroom head
is power dump.,pull out the mushroom head is power-on，when your truck is out of control,
please press the mushroom head to cut off power to avoid the accident.
（7）Pedal and guardrail: The operation mode of this truck is stand driving. Under normal
conditions, the standing pedal and guardrail should be open before driving the truck. During
operation of the truck, the driver should stand on the pedal. When the working area is relatively
narrow, the standing pedal and guardrail can be put away. Then, the maximum traveling speed
should not be over 4km/h.

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3.2 Main technical parameters (20EDPR Electric pallet truck)

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Characteristics
1.1
Manufacturer(abbreviated)
HHI
1.2
Model
20EDPR
1.3
Driving type：Electric(Storage battery),
diesel, gasoline, fuel gas
Electric
1.4
Operation type（Manual, Walking, Stand driving, Seat
driving ,Order picking）
Standing
1.5
Rated load
Q(kg)
2000
Rated load of the mast
Q(kg)
1000
Rated load of the rocker arm
Q(kg)
2000
1.6
Load center distance
c (mm)
600
1.8
Front overhang
x (mm)
767
1.9
Tread
Y (mm)
1348
Weight
2.1
Service weight(with battery)
kg
1130
2.2
Axle load, front/rear, laden
kg
1090/2040
2.3
Axle load, front/rear, unladen
kg
840/290
Wheel chassis
3.1
Wheels (rubber, high elasticity, pneumatic tyre,
polyurethane wheel)
PU wheel
3.2
Wheel dimension, front
Φ250× 70
3.3
Wheel dimension, rear
Φ80× 70
3.4
Additional wheel(dimension)
Φ127× 57
3.5
Wheel number, front/rear （x = drive wheel）
1X+2/4
3.6
Tread, front
b
10(mm)
490
3.7
Tread, rear
b
11(mm)
400/470
Dimension
4.4
Lift height
h
3(mm)
1600/2000/2500
4.6
Lift height of the support leg
h
5(mm)
120
4.9
Min. /Max. height of operation handle, in driving position
h
14(mm)
1150/1430
4.15
Fork height, lowered
h
13(mm)
90
4.19
Overall length
l
1(mm)
1898/1948
4.20
Length to face of fork
l
2(mm)
798
4.21
Overall width
b
1(mm)
775
4.22
Fork dimension
S/e/l(mm)
54× 180× 1100(1150)
4.25
Width overall fork
b
5(mm)
570/650
4.32
Wheelbase ground distance
m
2(mm)
28
4.33
Aisle width for pallet 1000x1200 crossways
Ast (mm)
2098/2148
4.34
Aisle width for pallet 800x1200 lengthways
Ast (mm)
2198
4.35
Turning radius
W
a(mm)
1600
Performance Data
5.1
Travel speed, laden/unladen
Km/h
9/9.1
5.2
Lift speed, laden/unladen
m/s
0.07/0.08
5.3
Lower speed, laden/ unladen
m/s
0.08/0.07
5.7
Gradeability, laden/unladen
%
8/20
5.8
Max. gradeability, laden/unladen
%
10/20
5.10
Traveling brake
Electromagnetic brake
M o t o r
6.1
Drive motor power
kW
1.5

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6.2
Lift motor power
kW
2.2
6.4
Battery voltage/rated capacity
V/Ah
24/240
6.5
Battery weight
Kg
200
Battery dimension（LXWXH）
mm
750× 170× 570
8.4
Noise level at operator’s ear, according to DIN12053
dB(A)
70
3.3 Installation position of warning label and nameplate
No.
Name
Remarks
1
Foot warning label
2
Operating warning label
3
Instruction lable of maintenance of
the battery
4
Nameplate
III.Operation instruction
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
stacker; check the truck whether it is in its normal condition before each operation. It is
forbidden to use faulty stacker; repair by untrained persons is forbidden as well.

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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.
1.1 Safety operation norms:
（1）Training of driver:
Even though each electric pallet stacker 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 stacker 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 tyre of

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truck is damaged, the noise may be amplified.
（5）Integrity of the truck shall be realized：
Warning
Do not make modifications on the truck.
APlease observe safety rules and regulations of your working place during operation,
inspection, and maintenance of the truck.
BUnauthorized truck modification is not permitted.
No modifications or alterations to a powered industrial truck, which may affect, for
example, capacity, stability or safety requirements of the truck,
（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:
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:
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

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person at both sides.
F Keep concentration when operating truck.
Caution The driving mechanism of truck is installed on the backside.
Due to this difference from common vehicles, the backside of truck swings comparatively
fast when turning around. For this reason, to prevent collision with other objects nearby the
backside of truck, do drive or turn slowly.
（2）Strictly forbid harsh driving
A Never start up, brake or turn abruptly。（ Abrupt start-up or braking may cause the falling of
goods.Abrupt turning during traveling may cause the tilting of truck and result in serious
accident.
Do decelerate and take care to turn.
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. (When
running on narrow road or platform, keep a certain safety distance with the edge against
falling of the truck).
Warning Avoid turning or loading and unloading operation on slope; otherwise the truck
can go tilting.
Warning Once the truck is overturning, the driver should stay far away from the truck rapidly.
Warning
（4）Forbid overloading operation.
（5）Passengers on truck must be forbidden.
（6）Never push or pull the handle abruptly.
（7）Never use the truck as towing vehicle.
2. Drive and operation
2.1 Inspection 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.

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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.
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 oil 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 device
Put the handle to B section, press the
emergency reversing device, see if the truck
can move forward
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Lifting, move button
Check if the lifting, movement of truck is
normal.
Warning Never use the faulty truck
2.2 Driving：
⑴Start-up
Get off the standing pedal and open the guardrail to turn the switch of electric lock to ON

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position. When the operation handle is turned to area B and accelerator knob is rotated slowly,
the truck will start gradually. The greater the accelerator knob is turned, the faster the truck
travels.
Warning When forking goods or moving goods, never rotate the accelerator knob rapidly
to speed up the truck abruptly.
（2）Deceleration
The drive motor is AC motor, the RPM of the motor is always
controlled by the speed controller, so when releasing the
acceleration knob slowly, the truck also slows dowm slowly to
decelerate.
When the working area is relatively narrow during operation, the standing pedal and guardrail
can be put away. Then, the maximum traveling speed should not exceed 4Km/h.
（3）Turning
The driver stands on the truck pedal in the right gesture and backs to the forks. When
the truck travels forward, 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 The driving mechanism of truck is installed on the backside. Due to this
difference from common vehicles, the backside of truck swings comparatively fast
when turning around. For this reason, to prevent collision with other objects nearby
the backside of forklift, do drive or turn slowly.
（4）Braking：Release the accelerator knob, then braking of the truck can be realized。
（5）Transportation operation
The following procedure shall be observed for goods transportation：
1) Decelerate when approaching the goods area;
2) Inspect safety condition around the stacking area;
3) Adjust position of the forklift, placing it in front of place where goods locate;
4) Slowly start the forklift, and insert fork arms to the bottom of goods as deeply as possible.
5) 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 stably, carry the goods to the destination, then adjust the position,
driving the truck to stop the arrival of shelf space and slow prong at a distance of 300mm
shelf unit, then operate the handle lifting fork up to proper height of the shelf (bottom of
the pallet is over the shelf 100mm or so), slowly move the goods to the exact position of
shelf. At last, operating the handle lowering fork, carefully placing goods on the shelves,
and made the forks leaving the cargo, slowly drive the truck, so that make the fork out of
the shelf (the fork head is in 300mm distance from the shelf), lower the fork down to about
300mm from the ground, the truck leave the shelves . It should be noted the obstacles
around in the process of moving, slow down when turning.
（6）The operation of taking down the goods from the shelf

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•drive the truck near the goods shelf (the fork head is in 300mm distance from the good
shelf), press the lift button, adjust the fork height into place, insert the fork slowly as
deep as possible into the goods pallets, press the lift button, operate the handle lifting
the goods to the height that the bottom of the pallet is 100mm over the shelf, slowly
drive the truck, so that make the goods out of the shelf (the fork head is in 300mm
distance from the shelf), press the lower button, lower the fork down to about
200-300mm off the ground, the truck leave the shelves.Then park the truck after
travel to the needed position, at last, lower the fork and the goods, make the fork leave
the goods completely, shift the fork out of the pallet slowly.
If the goods is very heavy and it need to carry a long distance, advice lowering the
fork to the lowest position to make the fork contact the support leg, lift the support leg to
make the goods leaving the ground to carry.
Before operating truck, do check the following items:
1. Ensure no goods falling and damaged in the loading area.
2. Ensure no goods or objects impeditive for safety.
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:
a) a. Lay down the fork to the lowest position naturally.
b) Turn the steering wheel to the middle position.
c) 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.
（4）After operation, the smudge on truck shall be wiped out. Besides, the following
check shall be carried out：
a. Keep visibility of all graphics context marks such as warning signs, nameplate and
notice board. These marks are able to instruct, caution and warn the operator to
some degree.
b. The situation about deformation, distortion, damage or breakage.
c. Add lubricating oil and grease if necessary.
d. Replace faulty components.

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Ⅳ．Maintenance, charge and replacement of battery
Standard configuration is external charger and the optional is built in charger. Charging
operation method as follow：
Outer charger
Charging ways for outer charger：
Open the cover,1, pull out the charging socket from main circuit；2，connect with
charging plug of battery and charger ；3，put the battery socket into two-phase AC
power supply；4,open the power switch;charge after a few seconds.

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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.
1. Initial charge
（1）Initial charge should be conducted for batteries that have never been used. Before the
initial charge, the surface of the batteries should be cleaned and the batteries should be
examined for damage. The bolts should be tightened to ensure reliable connection.
（2）Pull out the sealing cover and replace it with the open cover type liquid hole plug and open
the cover.
（3）When the charging equipment is able to operate normally, pour the sulfuric acid
electrolytic solution with a density of 1.260± 0.05 (25℃) and a temperature of lower than
30℃into the batteries. The liquid surface should be 15-25mm higher than the protective
board. In order to reduce the temperature rise caused by chemical reaction of the
electrolytic solution and let the electrolytic solution fully penetrate into the pores of the
polar plates and the baffles, the batteries should be placed still for 3-4 hours but not
exceeding 8 hours. The initial charging can only be conducted when the temperature of
the solution reduces to below 35℃. (When necessary, the batteries can be put into cold
water for temperature reduction). After the still placement, if the surface of the solution
reduces, electrolytic solution should be added.
（4）The sulfuric acid electrolytic solution is prepared with battery sulfuric acid complying with
the state standard GB4554-84 and distilled water. Never use industrial sulfuric acid and
running water. The standard temperature and density of the electrolytic solution can be
converted as follows:
D25 = Dt+ 0.0007 (t-25)
Where: D25: the density of the electrolytic solution at 25℃
Dt: the actual density of the electrolytic solution at a temperature of t ℃.
t: temperature of the electrolytic solution when testing the density.
（5）Sweep the electrolytic solution on the surface of the batteries and connect the positive and
the negative poles of the battery pack respectively with the positive and the negative
ends of the DC power supply (charger). Turn on the power supply. First charge with 18A
(the first stage current,); when the voltage reaches 28.8V (12 × 2.4V = 28.8V), change to
the second stage current 9A and continue to charge. The temperature of electrolytic
solution during the process of charging must not exceed 45℃and when it is close to 45℃,
the charging current should be reduced by 50% or the charging should stop temporarily.
Wait till the temperature drops to 35℃to continue the charging. The charging time,
however, should be properly prolonged.
（6）Fully charged basis: When the voltage during the second stage charging reaches 31.2V (12
× 2.6V = 31.2V), the variation of the voltage is no greater than 0.005 (V); the density of
the electrolytic solution reaches 1.280 ± 0.005 (25℃), no obvious variation in 2 hours and
there are fine air bubbles appear violently, it can be deemed that the batteries are fully
charged. The charged power capacity is 4-5 times of the rated capacity and the charging
time is about 70 hours.
（7）In order to accurately control the sulfuric acid content of the electrolytic solution, the

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electrolytic solution density of the batteries should be examined during the last period of
charging. If there is inconsistence, adjust with distilled water or sulfuric acid with a
density of 1.40. The electrolytic solution density and the liquid surface should be adjusted
to the stipulated value within two hours in the charging state.
（8）After the initial charging is completed, the surface of the batteries should be cleaned. Close
the cover of the open cover type liquid hole plug and then the batteries can be used.
2 Use and maintenance
（1）In order to guarantee the service life of the batteries, the batteries in use should be fully
charged. Insufficiently charged batteries must not be used. During the process of use,
close attention should be paid to the discharge extent. Over discharge is prohibited---the
voltage reduces to 1.7V per battery (when the total voltage reduces to 1.7V× 12 = 20.4V ).
When the density of the electrolytic solution reduces to 1.17, discharging should be
stopped and charging should be conducted at once. The batteries should not be placed
idle for a long period of time. The supplementary charging frequently conducted during
the process of use is called common charge.
（2）Common charge: The first stage current of common charge is 26A and that of the second
stage is 13A. The charging method is the same as that of initial charge. The charged
volume is 130-140 % of the discharged volume and the charging time is about 15 hours.
（3）The batteries in normal use should avoid over-charge, but over-charge must be properly
conducted for the batteries in the following situation, i.e. equalizing charge.
a. The “lag-behind” batteries--- batteries with a voltage lower than that of the other
batteries in the charging and discharging process and the batteries having been repaired
for failure. (When equalizing charge is conducted, the positive and negative poles of the
“lag-behind” battery should be respectively connected with the positive and negative
ends of the charger, the DC power supply, and the charge should be conducted
independently.).
b. Equalizing charge should be conducted for the batteries in normal use every 2-3
months.
（4）Equalizing charge
a. Charge with a 4A current.
b. When the charge voltage reaches 31.2V (12 × 2.6V = 31.2V) and air bubbles occur in
the electrolytic solution, the current should be reduced by 50% (2A) and continue to
charge.
c. When the batteries are fully charged, stop charging for 0.5 hour and charge again with
a 1A current for one more hour.
d. Stop charging for another 0.5 hour and charge with a 1A current for another one hour.
e. Repeat according to item d till air bubbles occur violently in the batteries once the
charger is switched on.
3Storage
Batteries should be stored in a clean, dry and well ventilated warehouse with a temperature of
5-40℃. The valid shelf life is 2 years. The batteries should be kept according to the following
requirements during storage:
a. No direct sunlight on the batteries and at least 2m away from heat source.
b. Avoid contacting with any harmful substances. No metallic matters are allowed to drop into
the batteries.
c. The batteries should not be placed upside down and should not be hit mechanically or heavily