Hyundai 30EPCR User manual

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30EPCR
Electric Pallet Truck
Operation Manual
Service Manual

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Welcome to choose “HYUNDAI” electric pallet truck!
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 ISO3691:1980 “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. applications ........................................................................................................... 1
2. service environment............................................................................................... 1
3. technical parameters.............................................................................................. 1
3.1 structure ...................................................................................................... 2
3.2 main technical parameters (30EPCR Electric Pallet Truck) ................................ 2
Ⅲ.Operation ................................................................................................................... 7
1Safety norms………………………………………………………………………………………………………..9
1.1 safety instructions......................................................................................... 9
1.2 safe driving standard…………………………………………………………………………………10
2. drive and operation...............................................................................................11
2.1 inspection before operation .........................................................................12
2.2 driving .......................................................................................................12
2.3 Important notice after operation ................................................................13
Ⅳ．Maintenance、charge and replacement of battery.......................................................14
1. initial charge...................................................................................……………………16
2 use and maintenance ...........................................................................................17
3 storage ................................................................................................................18
4 electrolyte operation ..............................................................................................18
5 storage battery operation of end service life ............................................................18
6.emergency treatment.............................................................................................18
7 battery charger......................................................................................................18
8. battery exchange ..................................................................................................17
Ⅴ. Maintenance and repair………………………………………………………………………………………….18
1. Maintenance.........................................................................................................18
1.1 precautions during maintenance ..................................................................20
1.2 check and maintenance before use ..............................................................20
1.3 routine inspection ........................................................................................20
1.4 inspection as needed....................................................................................21
1.5 inspection and maintenance .........................................................................21
1.6 recommended working medium ....................................................................22
1.7 structure of lifting cylinder and wearing parts ................................................23
1.8 maintenance period of consumable and component ..................................23
2. common faults and trouble shooting ......................................................................24
Ⅵ. Loading and unloading, transportation and storage of truck ........................................29
1. loading and unloading...........................................................................................29
2. transportation.......................................................................................................29
3. storage ...............................................................................................................29
Appendix I ......................................................................................................................30
Appendix II .....................................................................................................................31
Appendix III....................................................................................................................32

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Ⅰ．Specified use
The 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 not 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 relusts of department in charge do not represent the company opinion .
Ⅱ．Forklift introduction
1. Applications
30EPCR 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.

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3. Technical parameters
3.1 Structure
Number
CBD30Q
Name
1
●
Handle
2
●
Emergency Power disconnect SW
3
●
Instrument
4
●
Electrical control assembly
5
●
Drive unit
6
●
Electric lock
7
●
Lift button
8
●
Storage box
9
●
Battery
10
●
Hydraulic power unit
11
●
Steering power unit
12
●
Pedal
13
○
Warning lamp
14
○
Built-in charger
●=standard assembly ○=optional

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（1）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 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．Horn button 2. Lifting button 3. Accelerator knob 4. Slow button
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.
Electricity Quantity Indicator
Run-Time Display

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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.
When handle is out of area B, the truck can travel or lift, but it cannot
travel and lift simultaneously, and the travelling is prior.
③Horn button：Horn of the truck will be turned on if you press the button.
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：control the emergency power disconnect of the truck, power off when
pulling up, power on when pressing down. Please pull up this switch to cut off the power to
avoid the accident when the truck is out of control.

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3.2 Main technical parameters (30EPCR Electric Pallet Truck)

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Characteristics
1.1
Manufacturer(abbreviated)
HYUNDAI
1.2
Model
30EPCR
1.3
Driving type
Electric
1.4
Operating type （Manual, Walking, Stand
driving, Seat driving ,Order picking）
Standing
1.5
Rated load
Q(kg)
3000
1.6
Load center distance
c (mm)
600
1.8
Front overhang
x (mm)
1036/933
1.9
Tread
Y (mm)
2115
Weight
2.1
Service weight(with battery)
kg
1150
2.2
Axle load, front/rear, laden
kg
1390/2760
2.3
Axle load, front/rear, unladen
kg
860/290
Wheel chassis
3.1
Wheels (rubber, high elasticity, pneumatic
tyre, polyurethane wheel)
PU
3.2
Wheel dimension, front
φ250×80
3.3
Wheel dimension, rear
φ82×173
3.4
Additional wheel(dimension)
φ127×57
3.5
Wheel number, front/rear（x = driving wheel）
1X+2/2
3.6
Tread, front
b
10(mm)
620
3.7
Tread, rear
b
11(mm)
455
Dimension
4.4
Lift height
h
3(mm)
135
4.9
Min. /Max. height of operation handle, in
driving position.
h
14(mm)
1070/1370
4.15
Height, lowered
h
13(mm)
82
4.19
Overall length
l
1(mm)
2570
4.20
Length to fork face
l
2(mm)
1350
4.21
Overall width of truck body
b
1(mm)
823
4.22
Fork dimension
S/e/l(mm)
55x230x1220
4.25
Overall width of fork
b
5(mm)
685
4.32
Wheelbase ground distance
m
2(mm)
27
4.33
Aisle width, with pallet 1000x1200 crosswise
Ast (mm)
2790
4.34
Aisle width, with pallet 800x1200 lengthwise
Ast (mm)
2790
4.35
Turning radius
W
a(mm)
2290
Performance Data
5.1
Traveling speed, laden/unladen
Km/h
8/9
5.2
Lifting speed, laden/unladen
m/s
0.025/0.035
5.3
Lowering speed, laden/ unladen
m/s
0.03/0.03
5.7
Gradeability, laden/unladen
%
6/8
5.8
Max. gradeability, laden/unladen
%
8/20
5.10
Traveling brake
Regenerative brake
Motor
6.1
Driving motor power
kW
2.2
6.2
Lifting motor power
kW
1.5
6.4
Battery voltage/rated capacity
V/Ah
24/560(350/420/490/)
6.5
Battery weight
Kg
559

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Ⅲ. Operation
Warning
1. Safety Norms
Please pay attention to the following items first before operation of the truck：
1. This electric truck is only limited to utilization indoor with a hard flat floor. Operation in inflammable,
explosive environment or corrosive environment such as acid or alkaline condition shall be strictly forbidden.
2. Only drivers who have received formal training or are authorized can be allowed to drive the truck.
3. Read this instruction carefully before operation so as to master the performance of the truck; check the
truck whether it is in its normal condition before each operation. It is forbidden to use faulty truck; repair by
untrained persons is forbidden as well.
4. Overloading operation is forbidden.
5. As for goods carrying and operation, center of gravity of the goods must be within range of the two forks. It
is forbidden to transport loose goods.
6. The truck shall travels slowly when forks pass in or out of pallet.
7. It is strictly forbidden to press the lifting or lowering button during the traveling of the truck. Meanwhile,
don’t switch lifting and lowering buttons rapidly or frequently, because rapid and frequent lifting or lowering
will cause damage to the truck and goods
8. Don’t load heavy goods on the forks rapidly！
9. Don’t lay the goods on the truck for a long time！
10. It is strictly forbidden to make sharp turn on narrow aisle. When it is turning, slow down the truck so as to
ensure the safety of personnel and goods.
11. Descend the forks to the lowest position when the truck is not used.
12. It is strictly forbidden to put any part of the body under heavy goods and forks！
13. This truck is suitable to be used on flat ground or flat platform. Don’t put the truck on the slope for a long
time.
14. Overloading operation is forbidden. Otherwise the wheel will skid, resulting in the damage of wheel and
motor as well as danger of the human body and goods.
Battery dimension（L X W X H）
mm
780X335X625(490/550/595)
8.4
Noise level at operator’s ear, according to
DIN12053
dB(A)
70

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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 instructions
⑴Training 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.
.
⑵Wear 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.
.
（3）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.
（4）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.
AGood roadway condition shall be kept and the traffic should be smooth.
BSufficient light ray shall be ensured on working place.
CFire 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 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

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maintenance of the truck.
B No modification or addition shall be made to the truck without written permission by our company. A
modification of the truck may have a negative effect on its safe operation.
（6）Prepare safety operation procedure:
Safety operation procedure shall be formulated with consideration of practical situations before
operation of the truck. Safety shall be taken into full consideration in preparation of the safety operation
procedure..
（7）Operation of truck under unsafe condition is strictly forbidden:
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（drivers should pay more attention for
carrying extra-wide cargo.steering slowly and balance. Pay attention to the safety of all around meanwhile）
（10）Electrical System Check
Before checking the electrical system, turn off the key switches and the emergency isolation switches.
1.2 Safe driving standard
（1）Check the safety condition around the truck
A Before starting up the truck, please ensure that there is no person around it..
B If the driver’s view is shielded by the bulky goods carried, please drive backwards or drive under the
guidance of other working personnel..
C Ensure no people around the truck when driving backwards..
D Driving through the narrow access shall be guided by working personnel..
E At crossroad or other places impeditive for view, the driver shall not drive until there is no person at both
sides.
F Keep concentration when operating truck.
Caution
The driving mechanism of truck is installed on the backside. Due to this difference from common vehicles,
the back side 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

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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
1) Forbid overloading operation.
2) Passengers on truck must be forbidden.
3) Never push or pull the handle abruptly
4) Never use the truck as towing vehicle.

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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.
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.
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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
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Truck frame, etc
Damaged or not. If there is any crack.
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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
17
Lifting, move button
Check if the lifting, movement of truck is
normal.
Warning
Never use the faulty truck

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2.2 Driving：
⑴Start-up
Get on 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.
Warning
When forking goods or moving goods, never rotate the accelerator knob rapidly to speed up the
truck abruptly.
（2）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.
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 4Km/h.
（3）Turning
The driver stands on the truck pedal in the right gesture. 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. When the truck travel backward, if the
operation handle is rotated clockwise, the truck will turn counterclockwise. If the operation handle is
rotated counterclockwise, the truck will turn clockwise.
（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 and carry the goods to destination. Press lowering button and put the
goods on the ground, making the forks totally out of the bottom of the pallet. Then
backward the truck slowly；
Notice
Before operating truck, do check the following items:
1.Ensure no goods falling and damaged in the loading area.
2.Ensure no goods or objects impeditive for safety.

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2.3 Important notice after operation
(1) Parking: Park the truck at appointed place. Never park the truck on slope.
Ensure the following points to be achieved before leaving away the truck:
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
（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 storage battery
Standard configuration is external charger. Charging operation method as follow:
External charger
Charging ways for external charger:
Open the cover,the first step，pull out the charging socket from main circuit；step two，connect
with charging plug of battery and charger；step three，put the battery socket into two-phase AC power
supply；step four, open the power switch, it starts to charger in a few senconds.
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
1．1 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.

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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 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..
1．4The 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.
1．7 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.
1．8 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
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 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

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for the batteries in following situation, i.e. balance charge.
a. 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 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.
4、Electrolyte operation
⑴Density check
The suction type densimeter shall be used to check density. During operation, avoid spilling out the
electrolyte, and do wear protection appliance.
⑵Operation besides check
Consult professional personnel, especially when complementing electrolyte (dilute sulfuric acid).
⑶Electrolyte leakage
As for the electrolyte leakage resulting from storage battery tilting and damage, emergency treatment shall be
made at once (See emergency treatment item).
5、Storage battery operation of end service life
⑴Operation of storage batteries during the final stage of their lifetime
When the lifetime of storage battery is about to terminate, the electrolyte in single battery reduces very
fast. For this reason, distilled water shall be complemented everyday.
⑵Treatment of waste battery
As for the waste battery, draw out the electrolyte and decompose the battery. It can be discussed that whether
the waste battery shall be recycled by the battery manufacturer. The waste electrolyte can be disposed
according to relevant local rules and regulations
6、Emergency treatment
⑴The electrolyte spills on skin: wash with large amount of water

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⑵The electrolyte spills into eyes: wash with large amount of water, and then seek help from specialized doctor.
⑶The electrolyte spills on clothes: take off clothes right away, wash with water, and then flush with week
basic soap solution.
⑷The electrolyte leakage: in case of electrolyte leakage outside, neutralize it with lime, strong carbonic acid
soda or carbonic acid soda, and then flush with large amount of water.
7、Charger
If the charger you use is full automatic type. It must meet with the following 2 requirements:
a. The output voltage of charger: 24V
b. The output current of charger: 30A
If the charger you use is semi-automatic or manually adjustable, please charge the battery pack according to the
requirements of use and maintenance mentioned in the second tip
8. Replacement of storage battery
The weight of battery pack is about 240kg, and the replacement procedure of storage battery is as follows:
1. Open the side door of storage battery and take it down.
2. Pull down the socket connector of storage battery from the truck.
3. Turn up the handle of battery locking mechanism to loosen the battery.
4. Pull out the storage battery from the side way and take the storage battery away with special
car or using hoisting method.
5. The mounting method of putting the storage battery back into the battery pack is opposite to
the above procedures.
Note
Handle the storage battery gently during hoisting and transportation of the battery. Otherwise it
will cause damage to the battery or bring danger to human body.