Hyundai 20EPR User manual

 Operation Manual
 Service Manual

Welcome to choose “HYUNDAI” electric pallet truck!
We hope our electric trucks will bring great convenience to our
work!
 Please read the manual carefull before operation.
 This manual is a common manual. We reserve the right to modif
technolog of the electric pallet truck. If there is an thing in the
manual that is not consistent with the actual truck, the actual truck
should be considered correct and the manual is onl for reference.
***************************************************
Warning
 Operators must strictly conform to ISO/DIS 3691-1 3:2008 “Safety Specifications of Motor Industrial
Vehicles” Untrained personnel are not allowed to operate the truck

Content
Brief introduction…………………………………………………………………………………………… 1
Ⅰ Technical parameters ……………………………………………………………………………… 2
Ⅱ Structure description ……………………………………………………………………………… 4
Ⅲ Safety norms ……………………………………………………………… ………………………… 6
Ⅳ Drive and operation ………………………………… ……………………………………………11
Ⅴ Storage battery and charge ……………………………………… ………………………… 14
Ⅵ Inspection before operation ………………………………………………………………… 18
Ⅶ Inspection after operation ……………………………………………………………………18
Ⅷ Periodic maintenance and repair …………………………………………………………19
Ⅸ The storage of the pallet truck …………………………………………………………… 24
Ⅹ The tow of the pallet truck …………………………………………………………………… 25
Ⅺ Common fault and troubleshooting ………………………………………………………28
Appendix Ⅰ: Motor industrial vehicle—Safety norms ……………………………… 36

- Unauthorized 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, shall be made without the prior written approval of the original truck
manufacturer, its authorized representative, or a successor thereof. his includes changes affecting, for
example braking, steering, visibility and the addition of removable attachments. When the manufacturer or its
successor approve a modification or alteration, they shall also make and approve appropriate changes to
capacity plate, decals, tags and operation and maintenance handbooks.
- Only in the event that the truck manufacturer is no longer in business and there is no successor in the interest
to the business, the user may arrange for a modification or alteration to a powered industrial truck, provided,
however, that the user shall:
a) Arrange for the modification or alteration to be designed, tested and implemented by an engineer(s) expert in
industrial trucks and their safety;
b) Maintain a permanent record of the design, test(s) and implementation of the modification or alteration;
c) Approve and make appropriate changes to the capacity plate(s), decals, tags and instruction handbook;
d) Affix a permanent and readily visible label to the truck stating the manner in which the truck has been
modified or altered together with the date of the modification or alteration, and the name and address of the
organization that accomplished the tasks.

1
Brief introduction ：
20EPR/25EPR 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 As this truck is electrically driven for
traveling and lifting, it possesses many characteristics as labor-saving, high efficiency, stability in operation, simple
and easy operation, safety and reliability, little noise and environmental friendly, etc This truck adopts 24V large
capacity battery cell, which greatly extends service time within one charge
The kind of truck is applicable for goods transportation on hard and flat ground
Allowed environment for using : Height above sea level shall not be over 1000m;
a Ambient temperature shall not be higher than +40℃ and no lower than -25℃;
b When the ambient temperature reaches +40℃, the relative humidity should not exceed
50%; at a lower temperature, higher relative humidity is allowed
c Hard and flat ground
d It is prohibited to use the truck in a flammable, explosive or corrosive environment with
acid and alkali
Description:
The instruction manual shall be kept by the operator, and shall be read by the operator until he gets a full
understanding
The instruction manual is composed of correct operation, convenient and simple maintenance, and routine
inspection
The instruction manual shall be carefully read before operation, for purpose of correct drive and suitable
maintenance to ensure safe and effective material transportation
The instruction may be in disagreement with practical product due to product innovation
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
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

2
I. Technical parameters:
1．
．．
． 20EPR/25EPR Outline drawing：
：：
：

3
2、
、、
、Main technical parameter
Characteristics
1 2
Model 20EPR 25EPR
1 3
Driving model ：Electric(storage battery),
diesel, gasoline, fuel gas
Electric Electric
1 4
Driving model （Manual, Walking, Stand
driving, Seat driving ,Order picking） Stand driving Stand driving
1 5
Rated load Q(kg) 2000 2500
1 6
Load center distance c (mm) 600 600
1 8
Front overhang x (mm) 818/868/938 818/868/938
1 9
Tread Y (mm) 1302/1352/1422 1302/1352/1422
Weight
2 1
Service weight(with battery) kg 720 720
2 2
Axle load, front/rear, laden kg 1640/1030 2040/1180
2 3
Axle load, front/rear, unladen
kg
160/560 160/560
Wheel chassis
3 1
Wheels (rubber, high elasticity, pneumatic
tyre, polyurethane wheel) polyurethane polyurethane
3 2
Wheel dimension, front Φ250×70 Φ250×70
3 3
Wheel dimension, rear Φ80×70 Φ74×70
3 4
Additional wheel(dimension) Φ127×57 Φ127×57
3 5
Wheel number, front/rear （x = driving
wheel） 1X+2/4 1X+2/4
3 6
Tread, front b
10
(mm) 491 491
3 7
Tread, rear b
11
(mm) 340/370/470/505 340/370/470/505
Dimension
4 4
Lift height h
3
(mm) 120 120
4 9
Min /Max height of operation handle, in
driving position
h
14
(mm) 1150/1450 1150/1450
4 15
Height, lowered h
13
(mm) 75/85 75/85
4 19
Overall length l
1
(mm) 1823/1873/1943 1823/1873/1943
4 20
Length to fork face l
2
(mm) 723 723
4 21
Overall width of truck body b
1
(mm) 733 733
4 22
Fork dimension S/e/l(mm) 53×180×1100(1150/1220) 53×180×1100(1150/1220)
4 25
Overall width of fork b
5
(mm) 520/550/650/685 520/550/650/685
4 32
Wheelbase ground distance m
2
(mm) 30 30
4 33
Aisle width, with pallet 1000x1200 crosswise A
st
(mm) 2135/2185/2255 2135/2185/2255
4 34
Aisle width, with pallet 800x1200 lengthwise A
st
(mm) 2235/2235/2255 2235/2235/2255
4 35
Turning radius W
a
(mm) 1700/1750/1820 1700/1750/1820
Performance Data
5 1
Traveling speed, laden/unladen Km/h 7 9/8 6 7/6 8
5 2
Lifting speed, laden/unladen m/s 0 03/0 032 0 03/0 032
5 3
Descending speed, laden/ unladen m/s 0 032/0 03 0 032/0 03
5 7
Gradeability, laden/unladen % 4/8 3/8
5 8
Max gradeability, laden/unladen % 8/20 6/20
5 10
Traveling brake
regenerative brake
+electromagnetic brake
regenerative brake
+electromagnetic brake
Motor
6 1
Driving motor power kW 1 5 1 5
6 2
Lifting motor power kW 1 5 1 5
6 3
Battery voltage/rated capacity V/Ah 24/240 24/240
6 4
Battery weight Kg 240 240
6 5
Battery dimension（LXWXH） mm 650×250×505 650×250×505
7 1
Noise level at operator’s position dB(A) 73 73
7 2
Measurement uncertainty dB(A) 1 5 1 5
8 1
Vibration on till m/s
2
0 13 0 13
8 2
Measurement uncertainty m/s
2
0 05 0 05

4
Ⅱ. Structure description ：
1． Structure of the entire truck ：
1 Lifting button 2 Lowering button 3 Horn button 4 Emergency reverse button 5 Steering handle
6 Accelerator knob 7 Guardrail 8 Hydraulic power unit 9 Drive unit 10 Standing pedal
11 Charger； 12 Electric control assembly 13 Storage battery 14 Power switch 15 Electric lock
16 Instrument 17 Charging plug
2 Function introductions of instrument and operational control pieces: :
⑴ 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
Run-Time Display
Electricity Quantity Indicator

5
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
⑵ Steering system :
The steering system mainly composes of operation handle, steering device shaft, and floating support bearings The
system is used to control travel direction of the truck
⑶ 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
⑷ Operation control :
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
1． Lifting button 2 Lowering button 3 Accelerator knob 4 Emergency reverse button 5 Horn
6 Slow-down button
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 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,

6
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） 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 unexpected condition
5） Slow-down 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
6） 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
7） 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 Please immediately pull up the
switch to cut off power supply for sake of any occurrence of accident, if your truck were out of control due
to some reason
8） Charging plug: This plug is placed in the side hole of the truck And this plug is connected to the charger
with a spring cable When the battery needs to be charged, take down the plug and insert it into the socket
which is connected to network Then the battery can start to charge (Battery charger and its accessories
are optional parts of the truck, please consult with the authorized representative to buy authentic parts
This part shall fulfill the related safety requirements)
9) 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 6km/h
Ⅲ
ⅢⅢ
Ⅲ. Safet Norms：
：：
：
Warning
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

7
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． Safet operation norms ：
⑴ Training of driver：
Notice
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
⑵ Wear of the driver during truck driving ：
Notice
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
⑶ Rules that must be observed:
Notice
Never drive the truck when you are tired or un-concentrated, with an injection of drug, or after a liquor
drinking
 Safety rules and regulations shall be observed during operation or maintenance of the truck
⑷ Safety of working place ：
Notice
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

8
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 truck is damaged, the noise may be
amplified
⑸ Integrity of the truck shall be realized:
Warning
Do not make modifications on the truck
A
A A
A Please observe safety rules and regulations of your working place during operation, inspection, and
Maintenance of the truck
B
B B
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
⑹ 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
⑺ 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
⑻ Overloading operation of truck is forbidden:
W arning
Overloading operation of truck is forbidden Overloading operation would cause
damage to the truck or bring harm to operator
⑼ Use suitable pallet:
The pallet shall be of suitable dimensions, neither too wide nor too large
⑽ Electrical System Check:
Notice
Before checking the electrical system, turn off the key switches and the emergency isolation
switches
2 Safet Operation Specification ：
⑴ Check the safety condition around the truck:

9
Notice
Before starting up the truck, please ensure that there is no person around it
Notice
If the driver’s view is shielded by the bulky goods carried, please drive backwards or drive under the
guidance of other working personnel
Notice
Ensure no people around the truck when driving backwards
Notice
Driving through the narrow access shall be guided by working personnel
Notice
At crossroad or other places impeditive for view, the driver shall not drive until there is no person at
both sides
Notice
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

10
⑵ Strictly forbid harsh driving：
Notice
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
Notice
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
Notice
Ensure to provide certain clearance between truck and entrance
（3） Never drive too close to roadside ：
Notice
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
Notice
Once the truck is overturning, the driver should stay far away from the
truck rapidly
3
33
3 Operation norms :
Notice
The truck can only carry goods under rated capacity
1) Forbid overloading operation

11
2) Forbid deflective transportation
3) Passengers on truck must be forbidden
4) Never push or pull the handle abruptly
5) Never use the truck as towing vehicle
6) When transporting over-wide goods, the driver shall be extremely careful to turn slowly to keep balance of
the goods Decelerate when ascent and descent, meanwhile, watch around for sake of safety
7) The faulty truck for future repair must not be parked at places impeditive for traffic Lower down the fork
arms to the lowest position and put on the warning board Pull off the key
4
44
4 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) 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:
Notice
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
 Make a record of charge As for the charge method, refer to the part about storage battery operation
Ⅳ
ⅣⅣ
Ⅳ.
..
. Drive and operation ：
：：
：
1
11
1．
．．
． Prepare before operation ：
Warning
Never use the faulty truck
a) Before operation, check the truck to make sure: whether oil leakage of hydraulic pipe exists,
whether all the supporting wheels work well, whether blocking phenomenon appears Never use the
faulty truck
b) Check the charge quantity of storage battery Never use the truck with empty batteries Otherwise,
the lifetime of storage battery can be reduced greatly More seriously, the storage batteries can be
damaged
c) Check the braking of truck and the ascent, descent, running forward and backward

12
d) Turn the operation handle to the position of B area and press the emergency reverse button on top
of the operation handle to check that whether the truck can move forward or not
2.
2.2.
2. Driving ：
⑴ Start-up ：
Warning
When forking goods or moving goods, never rotate the accelerator knob rapidly to
speed up the truck abruptly
Get off the standing pedal and open the guardrail to turn the switch of electric lock to ON 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
⑵ 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
⑶ Turning ：
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 forklift, do drive or turn slowly
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
⑷ Braking ：
Release the accelerator knob, then braking of the truck can be realized
Notice
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 6Km/h.
6km/h

13
⑸ Transportation operation ：
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
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 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
① Decelerate when approaching the goods area
② Inspect safety condition around the stacking area
③ Adjust position of the truck, placing it in front of place where goods locate
④ Slowly start the truck, 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 steadily 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 drive back the truck
slowly

14
Ⅴ
ⅤⅤ
Ⅴ.
..
. Usage, maintenance and charge of storage battery
Schematic diagram of charging method
Charging operation method: The truck is equipped with a charger When the truck needs to be charged, first
open the cover of battery box to take out the charging plug from the side hole of the truck, then insert the charging
plug into the two –phase AC power Finally, the charger starts charging after several seconds (Battery charger and
its accessories are optional parts of the truck, please consult with the authorized representative to buy authentic
parts This part shall fulfill the related safety requirements)
1 Initial charge
1．1 Initial charge shall be made for new battery, i e The first time charge Clean up the surface of the battery
before the initial charge, and then check for damage to ensure reliable connection
1．2 Open gas cap
1．3 When the charging equipment is able to operate normally, pour the sulfuric acid electrolyte with
a density of 1 260±0 005 (25℃) and a temperature of lower than 30℃ into the batteries The
electrolyte level should be 15-25mm higher than the protective board In order to reduce the
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

15
temperature rise caused by chemical reaction of the electrolyte and let the electrolyte fully
penetrates into the pores of the polar plates and the baffles, the batteries should be placed still
for 3-4 hours, not exceeding 8 hours The initial charging can only be conducted when the
electrolyte temperature reduces to below 35℃ (When necessary, the batteries can be put into
cold water for temperature reduction) After the still placement, if the electrolyte level reduces,
electrolyte should be added
1．4 The sulfuric acid electrolyte 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 （25℃）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 t ℃
t: temperature of the electrolytic solution when testing the density
1．5 Dry up the electrolyte spilled on the surface of battery Connect the positive and negative poles of
batteries with those of D C source (charger) respectively and then turn on the power Charge
with the current of 30A (the current of the first stage) After the charge voltage achieves 28 8V
(12×2 4V=28 8V), switch to the 15A current of the second stage for continuative charge When
charging, the temperature of electrolyte shall never exceed 45℃ When the temperature raising
up nearly to 45℃, reduce the current by half or stop charging temporarily After the electrolyte
temperature reduce below 35℃, continue charging However the charge time need to be
extended appropriately
1．6 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 apparent changes 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
1．8 In order to accurately control the sulfuric acid content of the electrolytic solution, the 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
1．9 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
22
2 Use and maintenance
2．1 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

16
conducted during the process of use is called common charge
2．2 Common charge: The first stage current of common charge is 30A and that of the second
stage is 15A 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 12 hours
2．3 The batteries in normal use should avoid over-charge, but over-charge must be properly
conducted for the batteries in following situation, i e balance charge
a The “lag-behind” batteries--- batteries with a voltage lower than that of the other
batteries in the discharging process and the batteries having been repaired for failure
(When balance 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 Balance charge should be conducted for the batteries in normal use every 2-3 months
c Balance charge should be conducted for the batteries that have not been used for a long
period of time before use
2．4 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
electrolyte, 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
3 Keep and storage
The storage battery shall be kept in clean, dry and ventilated warehouse within the temperature range of 5 to 40℃
The valid storage period is 2 years Safekeeping shall be made within storage period according to the following
requirements:
a Avoid direct sunlight The distance from heat source shall not less than 2m
b Avoid contact with any harmful substance No metal impurity shall fall inside the battery
c No inversion, no mechanical collision or heavy weight is permitted
d Storage with electrolyte is forbidden Under special cases that the storage with electrolyte is necessary, the
density and solution level of electrolyte shall be adjusted to the specified value Whenever one month of
storage period expires, a complementary charge shall be made with the common charge method
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4 Operation of electrol te
⑴ Density check
The suction type densimeter shall be used to check density During operation, avoid spilling out the electrolyte,
and do wear protection appliance
⑵ Operation besides check
Consult professional personnel, especially when complementing electrolyte (dilute sulfuric acid)
⑶ Electrolyte leakage
As for the electrolyte leakage resulting from storage battery tilting and damage, emergency treatment shall be
made at once (See emergency treatment item)