Hyundai 30EPER User manual

30EPER
Electric Pallet Truck
 Operator’s Manual
 Service Manual

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.
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Warning
 Operators must strictly conform to ISO 3691“Safety Specifications of Motor Industrial Vehicles”.
Untrained personnel are not allowed to operate the truck.
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Content
Brief introduction………………………………………·………………………….1
Ⅰ. Technical parameters …………………………··…………………………….2
Ⅱ. Structure description……………………………·…………………………….4
Ⅲ. Safety norms………………………………………………………………….7
Ⅳ. Drive and operation…………………………··…………………………….12
Ⅴ. Storage battery and charge……………………………………………….14
Ⅵ. Inspection before operation……………………………………………….17
Ⅶ. Inspection after operation……………………···………………………….18
Ⅷ. Periodic maintenance and repair………………………………………….18
Ⅸ. The store and transportation of forklift…………………………………25
Ⅹ. The tow of the pallet truck……………………·………………………….25
Ⅺ. The disassembly and assembly of some parts………………………….26
Ⅻ. Common fault and trouble shooting…………………………………….30
Appendix: Motor industrial vehicle-Safety norms…………………………….36

1
Brief introduction：
30EPER series electric pallet truck is powered by storage battery, and driven by motor. This kind of truck
travels by means of gear drive. The fork is lifted by means of DC motor and hydraulic transmission, 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, such as labor-saving, high efficiency, stability in
operation, simple and easy operation, safety and reliability, little noise, environmental friendly, etc. And the
driving mode for this kind of truck is stand driving and steering operation of handle steering. 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:
a. Height above sea level shall not be over 1200m.
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.
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 dealer 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.

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I. Technical parameters :
1. 30EPER Outline drawing：

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2. Main technical parameter
Characteristics
1.1 Manufacturer HYUNDAI
1.2 Model 30EPER
1.3 Driving model：Electric(storage battery), diesel, gasoline,
fuel gas Electric(storage battery)
1.4 Driving model （Manual, Walking, Stand driving, Seat
driving ,Order picking） Stand driving
1.5 Rated load Q(kg) 2500
1.6 Load center distance
c (mm)
600
1.8 Front overhang
x (mm)
933
1.9 Tread
Y (mm)
1491
Weight
2.1 Service weight(with battery) kg 860
2.2 Axle load, front/rear, laden kg 1240/2120
2.3 Axle load, front/rear, unladen kg 640/220
Wheel chassis
3.1 Wheels (rubber, high elasticity, pneumatic tire,
polyurethane wheel) polyurethane wheel
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+2/4
3.6 Tread, front
b
10(mm)
691
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)
1041/1374
4.15 Height, lowered
h
13(mm)
82
4.19 Overall length
l
1(mm)
2143
4.20 Length to fork face
l
2(mm)
923
4.21 Overall width of truck body
b
1(mm)
936
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)
2343
4.34 Aisle width, with pallet 800x1200 lengthwise
Ast (mm)
2343
4.35 Turning radius
W
a(mm)
1860
Performance Data
5.1 Traveling speed, laden/unladen Km/h 7.5/8
5.2 Lifting speed, laden/unladen m/s 0.03/0.04
5.3 Descending speed, laden/ unladen m/s 0.05/0.045
5.7 Grade ability, laden/unladen % 6/8
5.8 Max. grade ability, laden/unladen % 10/16
5.10 Traveling brake regenerative brake
Motor
6.1 Driving motor power kW 2.2
6.2 Lifting motor power kW 1.5
6.3 Battery voltage/rated capacity V/Ah 24/300
6.4 Battery weight Kg 300
6.5 Battery dimension（L x W x H） mm 810×212×665
8.4 Noise level at operator’s ear, according to DIN12053 dB(A) 70

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Ⅱ. Structure description：
1．Structure of the entire truck：
1 Power switch 2 Lifting button 3 Horn button 4 Accelerator knob
5 Operation handle 6 Emergency reverse button 7 Multi-functional instrument 8 Electric lock
9 Electric control unit 10 Driving unit 11 Platform 12 Steering power unit
13 Hydraulic power unit 14 Storage battery 15 Handrail 16 Handrail control box
17 Tool pallet 18 Backrest

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2 Function introductions of instrument and operational control
pieces:
⑴ Instrument :
1. Battery capacity indicator；
2. Fault indicator；
3. Low-speed indicator；
4. Accumulative working time and fault code indicator
This instrument is a combination of battery capacity indicator,
LCD hour meter, fault code and low-speed indicator, with the
battery capacity indicator of five segments of colorful LED
display. When the storage battery is fully charged, the five
battery capacity indicators will be green. With battery capacity
consuming up, the five indicators will go out one by one. When
battery discharges by 70% capacity, the last indicator will flicker
and shows “energy storage” alarm. When the battery discharges
by 80%, the last indicator becomes red and shows “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.
⑵ Steering system:
The steering system mainly composes of operation handle, steering device shaft, support bearings,
potentiometer and steering power unit. The system is used to control travel direction of the truck.
⑶ Braking:
The traveling brake of this truck is regenerative braking, with parking brake of electromagnetic brake.
When the accelerator is released during the traveling of the truck, the controller will carry out
regenerat ive brak ing at first. Th is kind of brake 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 type of regenerative brake with electromagnetic brake not only prolongs the
service time of storage battery but also reduces the wearing of the brake plate, which extends the
service time of brake.
The position of operation handle is
divided into 3 areas, i.e. area A, area B and area
C which have different operational functions
separately.
Area A： When the operation handle is in area
A, the truck will be in a state of braking.
Then acceleration knob for traveling can not
work but can only conduct lifting or lowering
operation.
Area B： When the operation handle is in area
B, the truck will be in a state of traveling. When
the accelerator knob is turned to one direction,
the truck will travel in this direction. When the accelerator knob is turned in another direction, the truck will

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travel in another direction. When the accelerator knob is released during truck traveling, regenerative
braking will take effect, making the truck slow down to stop.
Area C：When the operation handle is in area C, the truck will be in a state of traveling. When the
accelerator knob is turned to one direction, the truck will travel in this direction. When the accelerator knob
is turned in another direction, the truck will travel in another direction. When the accelerator knob is
released during truck traveling, the truck will be in a state of free sliding.
When the operation handle is placed in area B or area C, the truck can conduct traveling
operation as well as lifting operation. However, traveling and lifting operation can’t realized at the same
time, with the traveling operation as the preferential function.
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 C shown as above. When the
handle is placed in area A, the truck will be powered-off and braked. At this time, the truck can’t
drive. When the operation handle is placed in area C 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
1. Horn button
2. Lifting button
3. Slow-down button
4. Lowering button
5. Power switch

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another direction. Likewise, 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 operat ion on especially narrow field or on the condition that the truck
needs to be accurately located.
6) Electric lock：It is used to cont rol swit ch ing-on and swit ch ing-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. If your truck were
out of control due to some reason, please immediately pull up the switch to cut off power supply
for sake of any occurrence of accident.
As for the operation button on operation handle and handrail control case, the same
buttons have the same control function, which is convenient for easy operation.
Ⅲ. Safety Norms：
Warning
Please pay attention to the following items first before operation of the truck:
⑴ 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.
⑵ Only drivers who have received formal training or are authorized can be allowed to drive the truck.
⑶ 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.
⑷ Overloading operation is forbidden.
⑸ 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.
⑹ The truck shall travels slowly when forks pass in or out of pallet.
⑺ 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.
⑻ Don’t load heavy goods on the forks rapidly.
⑼ Don’t lay the goods on the truck for a long time!

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⑽ 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.
⑾ Descend the forks to the lowest position when the truck is not used.
⑿ It is strictly forbidden to put any part of the body under heavy goods and forks.
⒀ 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.
⒁ 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.
⒂ It is strictly forbidden to use the truck under stipulated voltage of 20.4V.
⒃ It is strictly forbidden to conduct charge by connecting the plug to AC power directly.
1. Safety 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.
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 tire of truck is damaged, the noise
may be amplified.

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⑸ Integrity of the truck shall be realized:
Warning
Do not make modifications on the truck.
A Please observe safety rules and regulations of your working place during operation, inspection
and 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.
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:
Warning
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.

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2 Safety Operation Specification：
⑴ Check the safety condition around the truck:
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.

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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.
3 Operation norms:
Notice
The truck can only carry goods under rated capacity.
1) Forbid overloading operation.
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.

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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 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. Drive and operation：
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.

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2. Driving：
⑴ Start-up：
Warning
When forking goods or moving goods, never rotate the accelerator knob rapidly
to speed up the truck abruptly.
Turn the switch of electric lock to ON position. When the operation handle is turned to area B or area C 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
actuato r a ll the t ime. So, if the acce lerator knob is released slowly, the truck will slow down so as to decelerate.
Then, the truck will be in a state of sliding. When the operation handle is turned to area B, regenerative
braking take effect. And the truck will slow down until it stops.
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 faces the forks. When the truck travels forward,
if the operation handle is rotated counterclockwise, the truck will turn clockwise. If the operation handle is
rotated clockwise, the truck will turn counterclockwise. When running backward, 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：
Turn the operation handle to area B and release the accelerator knob, then braking of the truck can be
realized. While the operation handle is turned to area A, the truck will be in a state of braking, and traveling
function will be cut off.
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 procedures shall be observed for goods transportation：
① Decelerate when approaching the goods area；
② Inspect safety condition around the stacking area；

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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 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；
Ⅴ. Usage, maintenance and charge of storage battery
Schematic diagram of charging method
When it is necessary to conduct charging, please refer to the following operation methods:
1. Pull down the general power switch
2. Connect the charging plug of storage battery to output connector of charger
3. Then link the input connector of charger to AC power system
4. Turn on the charger, and it starts to charge after several seconds.
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
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 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 density of the electrolytic solution at 25℃
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. power source (charger) respectively and then turn on the power. Charge with
the current of 40 A (the current of the first stage). After the charge voltage achieves 28.8V
(12×2.4V=28.8V), switch to the 20A 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.

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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 40A and that of the second stage
is 20A. 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 10 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 charging and 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 chargin g for 0.5 hour and charge again with 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 electrolyte
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).
5 Operation of storage batteries during the final stage of their lifetime
⑴ Operation 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 daily.
⑵ Treatment 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.
6 Emergency treatment
⑴ The electrolyte spills on skin: wash with large amount of water
⑵ The electrolyte spills into eyes: wash with large amount of water, and then seek help from
specialized doctor.
⑶ The electrolyte spills on clothes: take off clothes right away, wash with water, and then flush
with week basic soap solution.
⑷ The 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: 40A
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.
Ⅵ. 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.
1 Check point and check content:
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.