Instruction Manual

XP Electric Pallet Truck

This Book Contains Important Information Regarding: SAFETY, ASSEMBLY, OPERATION,

MAINTENANCE and WARRANTY POLICY. Please Read And Keep This Book For Future Reference.
 Thank You For Choosing A Electric Pallet Truck

Welcome to use our electric pallet truck. Our truck is made of high quality steel and was
designed to give a durable, reliable and easy to use product.

The following pages contain instructions for using and maintaining the truck properly as well
as recommendations and directions for operating the truck efficiently and safely. We
recommend that you read this manual.

WARNING!
Read these instructions carefully, be familiar with the controls and the proper use of the truck.
Please keep the instructions safe for later use

Our pallet trucks are subject to ongoing development. Zowell reserves the right to alter the
design, equipment and technical features of the truck. No guarantee of particular features of
the truck should therefore be inferred from the present operating instructions.

Customer Service / Summary Information

• Contact your local dealer for any problems encountered with your pallet truck or spare
parts needs.
• Use only genuine spare parts to repair your pallet truck, thus keeping its technical
features intact.
• Refer to the spare parts catalog, available from your local dealer, for ordering spare parts.
• We recommend that you copy from the product label and / or plates the information in the
table below so that you can provide it to the dealer when necessary.

Product model
Serial No
Delivery date
Manufacturing Date
 Table Of Contents

CHAPTER 1………………………………………………………………………….…...Ⅰ
Introduction

CHAPTER 2……………………………………………………………………..………..Ⅱ
Safety

CHAPTER 3…………………………………………………………………….…….......Ⅲ
Technical data

CHAPTER 4………………………………………………………………………..……...Ⅳ
Learning about the truck

CHAPTER 5………………………………………………………………………..……...Ⅴ
Using the truck

CHAPTER 6……………………………………………………………………………….Ⅵ
Maintenance

CHAPTER 7………………………………………………………………………..………Ⅶ
Out of service

CHAPTER 8………………………………………………………………………..………VIII
The use of traction battery

CHAPTER 9………………………………………………………………………..………IX
Warranty policy and procedures
 Chapter 1 Introduction – General Instruction
1.1 – INTRODUCTION

1.1.a – General description

IMPORTANT:
Carefully read the warnings below before operating the truck:
- Many accidents result from insufficient knowledge or because safety instruction were not
observed while operating or maintaining the truck.
- The truck may only be operated by properly trained personnel. Contact your local dealer
for personnel training needs.
- To operate the truck properly and avoid accidents, the user must read, understand and
observe all the precautions and warnings contained in this manual and on the plates
attached to the truck.
- The truck may only be used in accordance with the regulations specified in its operating
instructions.
- The manufacturer declines any responsibility for accidents or injuries caused to people or
damage caused to objects resulting from users not observing the safety instructions
described in this manual.
- This manual must be kept carefully on board of the truck so that they can be quickly
accessed.
- Some of the illustrations in this manual show the truck without its protective devices
(guards, panels, etc.) in order to present the information more clearly.
Don’t use the truck without these protective devices. Maintenance operations must be
performed by qualified technicians ONLY.

1.1.b – customer service department

- For certain types of repair and maintenance work, contact your local dealer for a
qualified technician with the appropriate equipment and genuine spare parts.

1.1.c – Spare parts

- Use only genuine spare parts supplied by the manufacturer. Using unauthorized spare
parts will void the warranty and the user will assume full responsibility for any accidents
caused by the inadequacy of unauthorized parts.

1.1.d – Warranty policy

- The warranty policy is at the end of this manual, which contains the exact guarantee
period for different components.

1.1.e – How to use the manual

- This manual is divided into chapters covering different topics.
- The following symbols are used to indicate the safety messages contained in the manual:

DANGER TO PEOPLE
Not observing some or all of the instructions indicated by this symbol might
seriously compromise the safety of the driver or maintenance personnel.

DANGER TO THE TRUCK

Not observing some or all of the instructions indicated by this symbol might
cause serious damage to the truck, and in some cases void the warranty.

IMPORTANT INFORMATION
This symbol indicates important information for the driver.

SEE PARAGRAPH
This symbol indicates that the topic is covered in another paragraph.

1.2 – AREAS WITH THE RISK OF EXPLOSION

DANGER: Never use a standard truck in area where there is a risk of explosion
from gases, vapors, or inflammable and explosive powders, or areas threatened by
corrosion or excessive dust. Trucks that must operate in area where there is a risk of
explosion can be especially equipped upon request, and they must also be
accompanied by the appropriate instruction manual.

1.3 – TYPE OF USE AND INSTRUCTIONS FOR USE

The truck is intended for handing relatively stable loads only. Its forks can lift and carry any
type of load whose weight and load center fall within the specified parameters (see the
technical data).
It must be used for these operations only.
Normal conditions of use are as follows:
- Using the truck (moving and/or lifting) on surfaces that are relatively firm, smooth, flat
and adequately prepared.
- Using the truck with the center of gravity of the load more or less in the median
longitudinal plane of the truck.
- The load must be uniformly distributed on the forks.

The following are not normal condition of use because they may cause the truck to
accidentally overturn:
- Taking curves too quickly.
- Making sudden turns at a high rate of speed.
- Turning or moving sideways on inclines or going up and downhill.
- Carrying shifting loads or loads where the center of gravity is not in line with the median
longitudinal plane of the truck.
- Going up and downhill with the load facing downhill.
- Traveling over irregular surfaces (uneven surfaces, inclines or soft ground).
- Overloading the truck.
- Bumping into stationary and/or mobile structures.
- Misjudging the center of gravity of the load.

1.4 – USAGE PROHIBITIONS

- This truck has engineered and built to perform indoor material handing operations.
- Don not operate the truck in dusty or powdery environments where there is a potential
risk of explosion.
- Don’t operate the truck in salty environments, which may, over time, cause the electrical
or electronic components to malfunction due to corrosion.
- Don’t operate the truck in difficult conditions (extreme climates, cold stores, strong
magnetic fields, etc.), which may require special precautions, in which case contact your
local dealer.

IMPORTANT: See chapter 5 for information about using the truck in cold store
environments.
- Don’t operate the truck without using the “protective wire screen” or “additional screen”
whenever necessary, to prevent small objects from falling through the roof.
- Don’t operate the truck outside the following climatic limits.
⚫ Average ambient temperature for continuous use……………………….+25°C
⚫ Maximum ambient temperature…………………………………………….+40°C
⚫ Minimum ambient temperature for trucks operating in
normal conditions inside……………………………………………………+5°C
⚫ Altitude…………………………………………………………………up to 2000m
⚫ Relative humidity……………………Between 30-95% (without condensation)

1.5 – DESCRIPTION OF THE TRUCK

The truck offers the following features:
• It’s a vehicle on wheels for carry loads;
• It’s battery-powered;
• It’s tiller-steered;
• It is a truck equipped with forks for lifting pallets from the ground and carrying them
• It is built for carrying loads with a specific weight and volume.

1.5.a – Fastening attachments

- The mounting or installation of additional equipment which affects or supplements
the performance of the industrial truck requires the written permission of the manufacturer.
In some cases, local authority approval shall be required. Approval of the local authorities
however does not constitute the manufacturer’s approval.

IMPORTANT: To use an attachment, contact your local dealer who will install and test
it, and update the carrying capacity plates. Mounting an attachment requires an
additional carrying capacity plate. The attachment must also be equipped with an
identification plate.

1.5.b – Modifications to the truck

Contact the dealer if any special modification to the truck are required for non-standard
uses.

IMPORTANT: Never modify the truck without prior authorization from the
manufacturer, in which case contact the dealer.

1.6 – TRUCK DELIVERY

- The truck is tested and inspected by the manufacturer before it leaves the plant. The
dealer must perform additional inspection before delivering the truck.
- Upon delivery, check that all the accessories ordered have been delivered together with
the instruction manual；

IMPORTANT: If the truck is delivered with additional attachments and fittings, they
must also be accompanied by the relative use and maintenance manuals.

IMPORTANT: Manuals must be kept carefully so that they can accompany the truck
throughout its life time.

After checking these requirements, confirm to be the dealer that they have been delivered.

1.7 – Proprietor responsibilities

Proprietor responsibilities: For the purposes of the present operator manual the
“proprietor” is defined as any natural or legal person who either uses the industrial truck
himself, or on whose behalf it is used. In special cases (e.g. leasing or renting) the proprietor
is considered the person who, in accordance with existing contractual agreements between
the owner and user of the industrial truck, is charged with operational duties.
The proprietor must ensure that the industrial truck is used only for the purpose it is intended
for and that danger to life and limb of the user and third parties are excluded.
Furthermore, accident prevention regulations, safety regulations and operating, servicing
and repair guidelines must be followed. The proprietor must ensure that all truck users have
read and understood this operator manual.

Chapter 2 Safety

2.1 – SAFETY INSTRUCTIONS

IMPORTANT:
Below is a list of some safety instructions that must be followed. These rules are part of and
don’t replace, the standards described in the manual that is provided with the truck.

2.1.a – General safety instructions

- The truck must be used by qualified and authorized individuals only.
- Don’t install any equipment on the truck unless it has been supplied or approved by the
manufacturer.
- Always maintain the truck in good condition, which is a prerequisite for keeping risks to a
minimum.
- Keep the warning labels on the truck in good condition, and replace them if they are
damaged.
- Carefully read and follow all the safety instructions on the truck.
- Make sure that there is enough free space available above the truck.
- Don’t park the truck in front of fire extinguishers, emergency exit starts, or anywhere
where it can block traffic.
- If the truck shows signs of damage or breakage and it cannot be safety, stop the vehicle,
pack it, and notify the maintenance manager.
- Pay attention to the distance that must be maintained when working near overhead
high-tension wires. Observe the safe distances established by the responsible
authorities.
- Never lift the load using one fork only.
- Place the load next to the fork carriage assembly, or so that its load center is as close as
possible to the fork carriage assembly.
- Position the load so that center fails on the center line between the forks.
- Don’t drive with off-center loads with respect to the median axis of the truck. Doing so
might jeopardize the stability of the truck.
- Make sure that the surface supporting the load can carry the weight.
- Always use protective clothing as required by law.
- Don’t travel over uneven or obstructed ground or step.
- Don’t turn around or stack on slopes.
- Don’t overload the truck beyond the capacity limits on the appropriate labels.
- Always use the operator safety devices (for example, safety belt, etc).
2.1.b – Flooring requirements
The trucks are not equipped with a shock absorber system, so floors where they travel must
be even and without holes in areas that could create a problem for the trucks. Steps must be
equipped with ramps to avoid bumping the wheel, which would reverberate through the
entire body of the truck.

DANGER: Never travel with the truck over cracks or damaged floors. Trash or
obstacles obstructing the work area must be removed immediately.

2.1.c – Safety instructions for operating the truck

- Be confident that the truck is safe and reliable.
- Become familiar with the truck so that you can accurately describe malfunction and thus
be of assistance to the maintenance technicians. Trained and authorized drivers must be
familiar with the controls and function of the truck.
- Report any malfunctions (unusual noises, leaks,etc.) immediately because they could
result in damage of a much larger scale if ignored.
- Perform the inspections described in the chapter “Daily inspections”.

IMPORTANT:
Report any oil and/or battery liquid leaks because they are dangerous and highly polluting
substances.

ATTENTION:
If there is a smell of burning, stop the truck, switch off the engine, and unplug the battery.

2.1.d – Safety instruction for supplies

Hydraulic oil
- Avoid contact with the skin.
- Don’t inhale oil vapors.
- Never dispose of oils in the environment because they will pollute water. Collect them
and take them in legally approved containers to a collection center.
- Always wear protective clothing when performing maintenance operations on the truck
(glove, glasses, etc.), to prevent oil from coming into contact with the skin.

DANGER:
It’s extremely dangerous if hydraulic oil leaks under pressure and penetrates the skin.
Consult a doctor immediately if this occurs.

DANGER:
Oil squirting at high pressure can penetrate the skin.
Use a piece of cardboard to locate any leaks.

Battery acid
- Don’t inhale the vapor because it’s toxic.
- Use appropriate protection to avoid contact with the skin.
- Rinse with plenty of water if contact with battery acid occurs because it’s corrosive.
- Make sure that battery-charging areas meet all legal regulations due to the risk of mixing
explosive gasses.
- Don’t smoke or use an open flame or light within a 2-meter radius of the battery while it’s
being charged, or in the battery–charging area.

IMPORTANT:
See also the use of traction battery for further information.

2.2 – LOCATION OF THE WARNING LABELS

2.2.a - Operation caution scutcheon

2.2. b – the sign of Lifting

2.2. c – Battery maintenance items

2.2. d– Notes of battery using

2.2.e- operation caution

2.3 SAFETY DEVICES

The truck has been designed to provide maximum safety to the operator and minimum risk
of damage to the truck.
Some of the safety devices on the truck include the following:
1) Crush prevention safety button.
2) Emergency stop button.
3) Safety guards fastened with screws.

The truck is also equipped with electric and/or electronic devices to protect the motors and
the control unit.

Chapter 3 Technical Data- Identification of The Truck

3.1 – XP DIMENSIONS
 Note:

Pallet length

3.2 - XP ELECTRIC PALLET TRUCK TECHNICAL DATA

1 Product model designation XP20 XP25
2 Drive unit Electric Electric
3 Operate type Standing or Pedestrian
identification

4 Load capacity Q kg 2000 2500

5 Load center C mm 600 600
6 Load distance, center of drive axle to X mm 182 182
fork back
7 Wheelbase Y mm 1426 1426

1 Truck weight(without battery) kg 365 380

weight

2 Axle loading , loaded(from/rear) kg 965/1595 1154/1915

3 Axle loading , unloading(front/rear) kg 434/126 445/129

1 Tires Polyurethane Polyurethane

wheel

2 Drive wheels size mm Ф230×75 Ф230×75

3 Loaded wheels size mm Ф80×70 Ф80×70
4 Balance wheels size mm Ф100×40 Ф100×40
5 Wheels number, front/rear(x=driven 1x-2/4 1x-2/4
wheels)
 6 Tread ,front mm 510 510
7 Tread ,rear mm 400 400

1 Height, mast lowered h1 mm 1280 1280

2 Lift height h3 mm 205 205
3 Forks height, lowered h5 mm 85 85
dimensions

4 Height of tiller in drive h6 mm 1200/985 1200/985

Position(max/min)
5 Overall length L1 mm 1770 1770
6 Length to face of forks L2 mm 620 620
7 Overall width b1 mm 725 725
8 Fork dimensions s/e/l mm 160/55/1150 160/55/1150
9 Maximum forks width b3 mm 520/560/680 520/560/680
10 Minimum ground clearance M mm 30 30
11 Aisle width for pallets 800x1200 Ast mm 2047 2047
lengthways
12 Turning radius Wa mm 1615 1615

1 Travel speed loaded/unload Km/h 5.2/6 4.8/5.6

2 Lift speed loaded/unload mm/s 40/50 40/50
performance

3 Lowering speed loaded/unload mm/s 50/40 50/40

4 Max grade ability loaded/unload % 8/15 8/15
5 Service brake Electromagnetic Electromagnetic
brake brake

1 Drive motor rating kw 1.2 1.5

Electric

2 Lift motor rating kw 0.8 0.8

motor

3 Battery voltage/capacity V/Ah 24/210 24/210

4 Battery weight kg 240 240

1 Control unit type Mosfet control Mosfet control

others

2 Sound level Db(A) <70 <70

3.3 - NOISE
The value is determined in a test cycle in accordance with European Standard EN 12053
with time percentages of the translation, lifting and idling modes. It can only be used as a
comparison value for different forklifts.

IMPORTANT: Noise values that are lower or higher than those indicated above can
occur during actual forklift use, for example, following different operating modes, different
environmental conditions, additional noise sources.
3.4 - IDENTIFICATION OF THE TRUCK
- The truck and its main parts have serial number so that they can be identified.
- The serial numbers must be provided to the dealer for maintenance service or spare
parts needs.

3.4.a - Truck identification plate

XP Electric Pallet Truck

Model xxx Max. Lifting Height xxx mm
Serial No xxx Truck Weight xxx kg
Self Weight xxx kg Battery Capacity xxx Ah
PROD Year xxx Battery Voltage 24V
Equipment Code xxx Battery Weight Min. Max. kg

Lifting Height xxx mm xxx mm

Loading Capacity xxx kg xxx kg
Suzhou Pioneer Material Handling Equipment & Technology Co., Ltd
Note:
⚫ Please find the blank information in the label and/ or plates on the truck.
⚫ For queries regarding the truck or ordering spare parts always quote the truck serial
number.

DANGER!
The values indicated on the carrying capacity plate apply to compact, uniform loads that
must not be exceeded in order not to compromise the stability of the truck and the durability
of the framework. The distances of the center of gravity of the load and the lift height of the
forks determine the maximum transportable load.

3.5 - TRANSPORTING AND LIFTING THE TRUCK

3.5.a - Transporting the truck
The truck is usually transported by road or rail fully assembled. If the
truck is bigger than the permissible limits, it must be disassembled
and reassembled by the dealer. Make sure that the truck is
adequately secured during transport, with blocks placed under the
wheels to prevent any chance movements.

3.5.b - Climatic conditions for transporting and storing the Truck

The truck must be transported and stored protected from the weather
3.5.c - Loading and unloading the truck
Load and unload the truck by means of a ramp or mobile platform. If the truck is not
operational, follow the instructions below to lift the truck.

DANGER:
Use a crane that is big enough to handle the weight of the truck, indicated on the information
plate.
Make sure that the truck is lifted by qualified personnel only.
Don’t stand within the radius of action of the crane or under the raised truck.
Use NON-METALLIC cables. Make sure the cables can support the weight of the truck.

Chapter 4 Learning About The Truck

4.1 - OVERALL VIEWS

1- Tiller mechanism
2- Tiller
3- Battery status indicator and hour counter
4- Battery compartment cover
5- Removable guards
6 - Fork

4.2 - DEFINION OF THE DIRECTION OF TRAVEL

The manual defines the direction of travel as follows:
A = Direction of travel toward the operator
B = Direction of travel toward the forks
The preferred direction of travel is “A”.

4.3 - INSTRUMENTS AND CONTROLS

4.3.a - Tiller controls

1 = Safety button to prevent crushing.

2 = Traction control butterfly.
3、4 = lift control button
5 = Acoustic signal button.

IMPORTANT:
All the traction and lift controls are available when
the tiller is in the working position.

Crush prevention safety button (1)

- If the button (1) is pressed when the truck is
traveling toward the operator, it will travel oppositely and come to a stop

Traction control butterfly (2)

- If the butterfly control (2) is turned direction “A”, the truck will travel in the direction of the
forks. If the butterfly control is turned in direction “B”, the truck will travel in the direction of
the operator.
- If the butterfly is released, the truck will brake (electric braking upon release), and then
come to a stop.
- The speed of the truck increases depending upon the angle of the butterfly control.

IMPORTANT:
The speed of the truck will be reduced if the forks exceed the height recommended by the
manufacture, which may vary depending upon the carrying capacity of the truck, the type of
the mast used, and the level of oil in the reservoir.
Lift control button(3、4)
- press the button(3) to raise the forks
- press the button(4) to lower the forks

Acoustic warning button (5)

- Press the button (5) to sound the warming signal.
This device allows the operator to signal his presence when necessary.

4.3.b - Tiller positions

Functionality of the controls with respect to the position of the tiller instruction for the
standard tiller.

The tiller has three positions:

Position “1” = braking position;
- In this position, the traction function is locked and the parking brake will be applied.

ATTENTION : Don’t use this type of braking as braking system.

Position “2” = working position;
- In this position, the operator can drive the truck and operate the forks by means of the
appropriate controls.

Position “3” = braking position;

- In this position, traction is disabled and the parking brake is applied.
 ATTENTION : Don’t use this type of braking as braking system.

IMPORTANT:
- In this position, the lift function of the forks and frame members, if present, is locked out.
- In this position, the forks and arms (if present) will lower as normal.

IMPORTANT:
After releasing the tiller, it will automatically return to position “A”, which is the braking
position.

Instructions for using the tiller with the “tiller always enabled” function

With respect to the standard tiller, the tiller with the “tiller always enables ” function differs
only in tiller position “3”.
This function allows the operator to drive and operate the forks even when the tiller is in
position “3”.

IMPORTANT: When the tiller is released, it will automatically return into position “A”,
the braking position.

IMPORTANT: Recharge the battery at the latest before it’s 70% discharge (LED 2
blinking); the forklift does not lift below this threshold.

4.4 - CONTROL PANEL

4.4.a - Emergency stop button (1)
- Press the emergency stop button (1) (position B) to bring all the function of the truck to
a stop.
- To bring the truck back into operation, correct the
reasons for the emergency then proceed as follows:
- Release the tiller into the rest position “A”.
- Release the emergency button (1) (position C) by
pulling it up.

DANGER: This button should only be used if

necessary. Repeated use of this button may cause the
electronic system to malfunction.

4.4.b – Start/stop switch (2)

The switch (2) is in one of two position:
D = The machine is switched off. (The key is
D E
removed)
E = The machine is switched on.

4.4.c. - Battery status indicator and hour counter

The instrument is subdivided into two zones as follows;
Zone A
- Indicates the actual truck operation time, expressed in
hours.
- When the counter is working, clock “A1” blinks, five
numbers plus one decimal digit are displayed. The hours
are counted progressively. The hours are counted
progressively and start from zero.
Zone B
- Indicates the battery charge level; it’s subdivided into ten
sectors with respective colored LEDS.
- When the battery is 100% charged, LED 10 remains lit up.
- As the battery discharges, the LEDS light up one at a time
from right to left, starting from LED 10, which indicates the
completely charged battery status.
- When the battery is 70% discharged, LED 2 blink,
indicating that the battery is on reserve and must be
charged. Bring the truck to the charging area and charge
the battery.
- When the battery is 80% discharged, LEDS 1 and 2 blink
alternately. Lifting is blocked at this discharge threshold.

IMPORTANT: Recharge the battery at the latest before it is 70% discharged (LED 2
blink); the truck does not lift below this threshold.

4.5 – ACCESS TO THE INSIDE

To access the inside of the truck (electronic, electric and mechanical parts), please refer to
the “Maintenance” chapter. To access the battery (1) and the socket/plug (2), raise the cover
(3).
4.6 - OPERATING FOOTREST (optional, not standard part)
To raise or to lower the footrest (1) is freedom. When the operator drive truck in the sense of
the narrow, we can raise it (2). Obviously we can lay down the footrest in the sense of the
width（3）. Standing on the footrest can be more comfortable to operate the truck (A-B-C).

Chapter 5 Using The Truck

5.1 - DAILY CHECKS BEFORE USE

DANGER:
It’s a good rule to perform the daily checks listed below to maintain the truck in good
condition.
These checks are part of, and don’t replace, the scheduled maintenance operations.
- Perform a visual check that the various parts of the truck are in the correct position: forks,
anti-shearing safety mesh or transparent guard.
- Check the position of the battery socket/plug.
- Check that the ignition switch is working correctly.
- Check that the acoustic warning signal is working correctly.
- Check that the buttons and butterfly control located on the tiller are working correctly.
- Check that emergency stop button is working correctly.
- Check that the tiller automatically returns to the vertical position after the emergency
brake has been applied.
- Check that the crush prevention button is working correctly.

DANGER: If something on the truck is malfunctioning or you are not sure if it’s
working correctly, don’t use the truck but contact the customer service department.

5.2 - USING THE TRUCK

5.2.a - Position of the operator
The operator steers the truck from the GROUND using the travel and lift controls located on
the tiller head.

5.2.b - Uses for truck versions with initial arm lift function
The line of truck with initial arm lift function consists of two
versions a carrying capacity of 2000kg and 2500kg; these trucks
can be used for horizontal transporting.

Truck used for elevating (See figure at side)

5.2.c - Starting the truck

Proceed as follows after performing the daily checking before
using the truck:
- Insert the key (A) and turn it to the position, the battery status
indicator and hour counter will light up indicating the hours of
operation and the status of the battery.
- Make sure that the emergency button is not depressed.

5.2.d - Traveling
- Till the tiller into the working position.
- Turn the butterfly control (2) in the desired direction of travel. The
speed of the truck increases depending upon the angle of the butterfly control.
 IMPORTANT: If the truck doesn’t start easily, don’t persist but find out the reason
why.

5.2.e - Reversing the direction of travel

- To do this, turn the butterfly control (2) in the
opposite direction of travel. The truck will come to a
forceful but gradual stop, and then continue in the
opposite direction.

1 = Crush prevention safety button.

2 = Traction control butterfly.
3/4 = Lift control button.
5 = Acoustic signal button.

5.2.f - Stopping the truck

The truck can be stopped as follows:
1) Release the butterfly control;
2) Keeping the tiller position 1or 3 can also stop the truck.

5.2.g - Stopping the truck in an EMERGENCY

The truck can be stopped in an EMERGENCY as follows:
Press the button (above1).
After the emergency stop button has been enabled, proceed as
described in chapter 4.4.a.

5.2.h - Stopping the truck for a long period

- If the truck is going to be stopped for a long period of time, lower the forks to the ground.
Switch off the truck by tuning the key into the “0” position, then remove the key.

5.3 - ENGAGING AND DISENGAGING THE LOAD

5.3.a - Picking up the load

DANGER: Before picking up the load, make sure that the truck can handle its size and
weight as indicated in the “TECHNICAL DATA” chapter.

DANGER: Loads must be arranged so that they do not jut out from the load
support surfaces of the truck, nor slide or tip over and fall to the ground.
- Approach the load as carefully and closely as possible.
- Bring the truck slowly toward the center of the load to be lifted.
- Lift the load slightly from the support surface, pressing the fork lift button as described
in paragraph 4.3.a
5.3.b - Depositing the load
- Approach the area where the load is to be deposited.
- Lower the fork, pressing the fork lower button as described in paragraph 4.3.a, until the
load is deposited in the desired area, and withdraw the fork from the load.
- Withdraw the truck from the area.

5.3.c - Towing the load

- The truck is not equipped to tow the load.

5.3.d - Towing the truck

- The truck is not equipped to tow any truck.

5.4 - CHARGING THE BATTERY BY MEANS OF EXTERNAL BATTERY

CHARGER

DANGER: Switch off the truck before charging the battery.

IMPORTANT: Charge the battery in a location that complies with the regulations in
effect.

IMPORTANT: See the manuals provided with the battery and the battery charger for
the instructions on how to charge, etc. Make sure that the correct voltage is delivered.

IMPORTANT: See the battery manual and paragraph 2.1 of this manual for the safety
warnings.

- Lift the battery compartment hood (1) as described in the

relevant paragraph.
- Remove the battery plug (2) from the socket (3) of the
electronic system of the truck.
- Remove the caps if the battery is not equipped with a vent.
- Switch on the external battery charger.
- Connect the plug (2) to the battery charger to start charging .
- After charging the battery, switch off the battery charger.
- Remove the plug (2) from the battery charger.
- Replace the battery caps, if any.
- Reinsert the battery plug (2) in the socket (3).
- Lower the battery compartment hood (1).

5.5 - BATTERY CHARGE BY THE BATTERY-CHARGER ON BOARD (if

equipped)
 CAUTION: The battery must be charged with the truck motor off.

IMPORTANT: Charge the battery only in areas that meet the required regulations.

IMPORTANT: Refer to the battery manual and the relevant battery charger manual for
the method of charger, checking levels, etc. making sure that the correct voltage is
delivered.

IMPORTANT: Refer to the battery manual and paragraph 2.1 for safely instructions.

- When the charging is completed, the battery-charger will stop automatically.

- Put the plug back into its storage place.

5.6 - USE OF THE TRUCK WITH EXTENSION CORDS

DANGER: The truck may only be operated with extension cards up to a maximum
length of 20 meters if they are equipped with a filler and are approved by the manufacturer.

5.7 - USING THE “COLD STORAGE” TRUCK (optional)

This truck is operated in exactly the same way as the standard version, with the exception of
the temperatures in which the truck is operated.
The two versions differ only in the respect that the “cold stores” version can be used at a
different environmental temperature.
- The “cold stores ” version should be used in cold stores with a minimum temperature of
-32℃ and a maximum temperature of +25℃, or +40℃ for short periods of time.
- The “cold stores” version can be used alternately inside or outside the cold store.
- The truck should not remain outside the cold stores for longer than 10 minutes (to
prevent condensation from forming) or for less than 30 minutes (to allow the
condensation to evaporate).

DANGER: It’s absolutely prohibited to enter the cold stores with condensation on the
truck.

5.8 - RUNNING IN THE TRUCK

The truck doesn’t need a running in period.

IMPORTANT: To obtain maximum performance from the traction battery, follow the
manufacturer’s directions for the first time it’s used (see the use of traction battery.).

5.9 - MALFUNCTIONS – CAUSES – REMEDIES

This paragraph describes the various malfunction that may occur when using the truck, the
reasons they occurred, and how to remedy them.
If the malfunctions continue after performing all the suggested checks, please contact the
Customer Service Department.

Malfunction: Cause Remedy

The truck will not start. The battery plug is not Check the battery plug.
inserted, or is inserted
incorrectly.
The emergency stop button Lift up the emergency stop button.
is depressed.
The battery is discharged. Check the charge on the battery
and recharge it if necessary.
The sequence of operations Repeat the sequence of operations
has not been performed correctly.
correctly when switching on
the truck.
The traction butterfly control Turn the butterfly control in the
is not turned. desired direction of travel.
The ignition key is in the “0” Turn the switch into the “1” position
position (truck is switched (truck is switched on).
off).
The tiller is in the braking Move the tilled into the working
position. position.
The load cannot be The load is too heavy. Check that weight of the load to be
lifted. lifted is less than or equal to the
maximum capacity of the truck.
The truck not ready for Perform all the check described in
operation. the paragraph above “The truck will
not start”.
The level of hydraulic oil is Tap up the oil as described in the
too low. “Maintenance” chapter.
The battery is discharged. Charge the battery.

Chapter 6 Maintenance
6.1 - MAINTENANCE OPERATIONS
To keep the truck in good condition, it’s recommended that the maintenance operations be
performed in accordance with “Maintenance Operations Summary Table” on the following
pages.

In addition to the maintenance operations described in this chapter, there are other
operations that must be performed by the Customer Service Department. We recommend
that you contact the Customer Service Department to draw up a maintenance contract that
is appropriate for your truck.

There are two types of maintenance operations:

MAINTENANCE AS REQUIRED
SCHEDULED MAINTENANCE

DANGER: Maintenance operations must be performed by qualified technician who

has been approved by the manufacturer. Always follow the safety requirement for handling
supplies and the instructions described in chapters “1” and “2”.
Work in a designate maintenance area, or section off the area around the truck with
appropriate signs to indicate that work is in progress.

6.1.a - Preliminary maintenance operations

Proceed as follows before performing any maintenance operations.
- Place the truck on a level surface and make sure that it cannot suddenly move
- Lower the forks completely.
- Switch off the truck and remove the key.
- Press the emergency stop button.

DANGER: Remove the battery plug from the socket before performing any
maintenance operation on the electrical system.

6.2 - MAINTENANCE AS REQUIRED

Maintenance as required operations are performed
on an as needs basis, such as cleaning the truck,
repairing or replacing a worn or broken part.

6.2.a - Cleaning the truck

The frequency with which the truck is cleaned
depends upon how and where the truck is used. If
the truck comes into contact with harsh substances
such as salty water, fertilizers, chemical products,
cement, etc., it must be thoroughly cleaned after
every use.
Use compressed air and detergents with cold water.

ATTENTION: Don’t aim jets of water directly onto the truck,

and don’t use solvents or gasoline-based products because they
could damage the electrical and plastic parts.

6.2.b - Replacing the battery

- Switch off the truck and perform the preliminary maintenance
operations.
- Lift the battery cover (1).
- Remove the plug (2) from the socket (3).
- Remove the battery locks (4).
- Lift the pin (5) and remove the panel (6).
- Turn the additional roller (7) into position “A” (only
present).
- Loosen the knob (8) on the direction of the arrow.
- Place a stable surface to support the battery next to
the truck, and line it up with the battery compartment.
- Remove the battery by sliding it on the rollers inside
the truck, and place it on the support previously
prepared.
- Hook the battery at the two points (9) with a cable or
chain.
- Lift the battery with a hoist capable of supporting the
weight of the battery.
- Replace the battery and assemble it by following the procedure in reverse.

IMPORTANT:
Refer to chapter “TECHNICAL DATA” for the type of battery to use.

DANGER: Before operating the truck, check for the proper position of the battery clamp.
That must be as shown in the diagram, and check that the knob (8) is perfectly tightened.

6.2.c - Disassembling the hoods

DANGER: Safety hoods should be disassembled by a qualified technician only.

- Switch off the truck and perform the preliminary maintenance operations.
- Remove the emergency button head (1) by inserting a screwdriver into the hold (2), and
holding the button stem still with the screwdriver turn the head of the button in an
anti-clockwise direction until it comes off completely.
- Unscrew the screws (3) and remove the hood (4), being careful with the electrical wires
connecting the switch (5) and the instrument (6).
- Replace the hood (4) by following the above procedure in reverse, making sure that the
emergency button (1) is working properly.

6.2.d - Replacing the fuses

Switch off the truck and perform the preliminary maintenance operations.

DANGER: This operation must be performed by qualified technicians only.

DANGER: Before replacing the fuse, correct the reason that caused it to burn out. The
blown fuse must be replaced by a fuse with the same amperage. Don’t tamper with the
electric system of the truck.
- Remove the guard panel as described in the previous paragraph.
- The power fuse is the located on the electronic switch board. While the service fuses are
located in the appropriate fuse holders.
Power fuse
- Remove the screws, replace the fuse and replace the screws.

Service fuses
- Remove the cover and replace the blown fuse, then replace the cover.
Fuse values
FU1 = 200A power fuse
 FU2 = 10A fuse to protect the electronic system and tiller circuit board

6.2.e - Replacing the drive wheel

- Switch off the truck and perform the preliminary maintenance operations.

DANGER: This operation must be performed by qualified technicians only.

- Remove the wheel lugs (1).
- Raise the truck and place supports under the frame of the truck.
- Lower the truck and place it on the supports, keeping the cable taut.
- Completely remove the lugs (1) and remove the wheel (2).

6.2.f - Replacement / Adjustment of the pivoting wheels

- Replace or adjust the pivoting wheels when necessary by calling an authorized service
facility.

6.3 - SCHEDULED MAINTENANCE

Some scheduled maintenance operations may be performed by the company technician,
while others must be performed by the Customer Service Department.

DANGER: If the truck is used in dusty environments, in temperatures below zero, or

in demanding conditions, the scheduled maintenance operations must be performed more
frequently.

6.3.a - Overview table of maintenance operations

Intervals in operating hours Qualified
Operation
technician
10 100 1000 2000 300 CT SC
Check the level and density of the electrolyte ● ●
Check the tightness of the wheels ▲ ● ●
Check the wear and tear of the wheels ● ●
Grease the tie rods and levers ● ●
Clean the electric motors ● ●
Clean the motor manifolds ● ●
Check the wear and tear of the hoses ● ●
Check the level of hydraulic oil ● ●
Replace the hydraulic oil ● ●
Check the level of reducer oil ● ●
Replace the reducer oil ● ●
Check the chassis bearings ● ●
Check the lever bushings ● ●
Check the pivoting wheels ● ●
Check the electromagnetic brake ● ●
Greasing the reducer thrust ring ● ●
Checking the insulation between the frame ● ●
and electrical motors
Checking the insulation between the frame ● ●
and electronic control
Check the electromagnetic brake ● ●
Lubricating the slide-track of the forks ● ●
Check the insulation between the frame and ● ●
the electrical/electronic components
CT = Company technician
SC = Authorized service center
▲ = Frequency of maintenance until the end of the running in period

IMPORTANT:
Comments about the greasing operations
Observe the following requirements each time greasing operations are performed:
- Product safety warnings;
- Thoroughly clean the part involved;
- Use appropriate binders if the product spills;
- Store the product in an appropriate location;
- Dispose of the product in accordance with the law.

EVERY 10 HOURS

6.3.b - Checking the tightness of the wheels

- Perform this operation at the frequency specified in the above maintenance

table, and whenever a wheel is replaced.
- See the appropriate for instructions how to replace a wheel.
- The figures opposite show the order in which the wheel
lugs are tightened.
- The table below indicates the torque values for
tightening the lugs.

Drive wheel

120±5% Nm / 12±5% kgm

6.3.c - Checking the wear and tear of the wheels

- Replace the drive wheel if it shows signs of wear and tear (the surface is no longer
uniform or damaged).
- Replace the wheel as described in point 6.2.e.

6.3.d - Checking the level and density of the

electrolyte

- Raise the cover (1) and check the level and density of
the electrolyte as described in the battery instructions.

EVERY 1000 HOURS

6.3.e - Checking the level of hydraulic oil

- Check the level of hydraulic oil after placing the truck on a flat surface and with the forks
raised to the maximum height.
- Switch off the truck and remove the key.
- Visually check that the level of hydraulic oil by using a liquid indicator
Top up the oil if necessary by removing the cap and pouring the oil into the reservoir.

IMPORTANT: See the supplies table at the end of this chapter for the type of oil to
use.

6.4 - SUPPLIES TABLE

Part requiring supplies Lubricant
Hydraulic system YB-32
ISO-L-HM46
Reducer 85W/90.
SAE80W/90
Multi-purpose greasing 3# Lithium base lubrication drops 170
 Chapter 7 Out of Service

7.1- GENERAL DESCRIPTION

This chapter describes the operations to perform to take the truck “Temporarily out of
service” and “Permanently out of service”.

7.1.a - Temporarily out of service

Proceed as follows if the truck is not going to be used for a long period of time.
- Clean the truck as described in the “maintenance” chapter, and store it in a dust free and
dry location.
- Lower the forks.
- Lightly wipe the unpainted parts with oil or grease.
- Perform the greasing operation as described in the “maintenance” chapter.
- Remove the battery and place it in a location where there is no danger of freezing.
Charge the battery at least once a month.
- Raise the truck so that the wheels do not touch the ground, otherwise they will become
flattened at the point of contact.
- Cover the truck with a tarpaulin that is not made of plastic.

7.1.b - Checks and inspections after a long period of inactivity

DANGER: Proceed as follows before using the truck again:

- Clean the truck thoroughly.
- Check that the battery is charged, reassemble it in the truck, and grease the terminals
with vaseline.
- Grease all the parts that have lubrication nipples and the chains.
- Check the levels of the liquids.
- Perform all the operational maneuvers of the truck and check the safety devices, when
the truck is both loaded and unloaded.

DANGER: See the “maintenance” chapter for the operations described above.

7.1.c - Permanently out of service(scrap)

Proceed as follows if scrapping the truck.

DANGER: The truck must be dismantled by a qualified technician only.

- Dismantle as many of the truck parts as possible (panels, lights, battery, chains, motors,
etc.), and separate them according to the nature of the material (for example hoses,
rubber parts, lubricants, aluminum, iron, etc.).
- Notify the appropriate authorities in writing in accordance with the legal requirements of
each country before scrapping truck.
- Scrap the parts in accordance with legal requirements after receiving permission from
the appropriate authorities.

7.1.d - Disposing of toxic substances

- Check the local legal requirement for disposing of toxic substance such as lubricants,
batteries etc., and proceed as required.
- Dispose of used batteries in an environmentally responsible manner

WARNING!
Do not attempt to dispose of your battery in a fire. The cell may explode.

The battery contains lead cells. After their lifetime has expired, they must not be disposed of
as normal household rubbish, but must be disposed of properly.
Please dispose of the flat battery via you local municipal disposal point. It is essential to
return the battery or to dispose of it via your local municipal disposal point. Only hand over
the battery in a discharged condition.

IMPOERTANT: See the use of traction battery for further information.

IMPORTANT: The customer is entirely responsible for any irregularities involving

legal requirement before, during and after scrapping and disposing of truck parts.

Attachment：

1. Electrical principle
1 M1 Traction motor
 2 M2 Pump motor
3 DC Electromagnetic valve
4 d Electronic assembly
5 YK Key switch
6 ZD Electromagnetic brake coil
7 g1 RelayⅠ
8 g2 Relay Ⅱ
9 MS1 Mode switchⅠ
10 MS2 Mode switchⅡ
11 HS Interlock switch
12 JK Belly switch
13 a Control handle
14 b Backward
15 c Forward
16 JS Accelerator
17 LK Horn switch
18 SK Upward
19 XK Downward
20 XW Limit switch
21 DL Electricity HRS
22 LB Horn
23 SD Manual power outages
24 BX1 150A fuse
25 BX2 250A fuse
26 M Main contactor
27 P Pump contactor
28 MC Main contactor coil

2. Hydraulic principle
C Hydraulic jack

T Hydraulic tube

Vr Check Valve

F Filter

D Solenoid operated directional valve

E Flow control valve
Vm Pressure relief valves
P Pump
M Electric motor
S Tank
 Chapter 8 The Use of Traction Battery

1. General safety instructions

A battery should be kept clean.
A battery should be kept correctly charged.
A battery should have the electrolyte kept at the correct level.
A battery should not be exposed to excessive shocks or vibrations.

IMPORTANT!
When using the traction battery, The safety precautions and rules in this manual must be
observed to avoid injuries and damage. Please read the complete operating manual with
due care. Keep this manual in a safe place, so that the information is available at all times. If
you give the equipment to any other person, give them these operating instructions as well.
We accept no liability for damage or accidents which arise due to non-observance of these
instructions and the safety information.

IMPORTANT!
Carefully read the warnings below before operating the traction battery.

⚫ Pay attention to the operation instruction and fix them close to the battery!
⚫ Work on batteries to be carried out by skilled personnel only!

⚫ Use protective glasses and clothes when working on batteries!

⚫ Pay attention to the accident prevention rules as well as DIN EN 50272, DIN
50110-1!

⚫ No smoking!
⚫ Do not expose batteries to naked flames, glowing embers or sparks, as it
may cause the battery to explode!

⚫ Acid splashes in the eyes or on the skin must be washed with water. In case of
accident consult a doctor immediately!
⚫ Clothing contaminated by acid should be washed in water.

⚫ Risk of explosion and fire, avoid short circuits!

⚫ Electrolyte is highly corrosive!

⚫ In the normal operation of these batteries a contact with acid isn’t possible. If the
cell containers are damaged, the immobilized electrolyte (gelled sulphuric acid)
 is corrosive like the liquid electrolyte.
⚫ Batteries and cells are heavy!
⚫ Ensure secure installation! Use only suitable handling equipment e.g. lifting gear
in accordance with VDI 3616.

⚫ Dangerous electrical voltage!

⚫ Caution! Metal parts of the battery are always live. Do not place tools or other
metal objects on the battery!

Ignoring the operation instructions, repair with non-original parts and non
authorized interventions will render the warranty void.

⚫ The container used for mixing electrolyte should be acid proof and heat-resisting. First
pour certain amount of water into a heat and acid-resistant container slowly in the
proportion volume and stir the mixture at the same time so the sulfuric acid doesn't settle
on the bottom. Always pour acid into water, never pour water into acid because a
dangerous violent chemical reaction can occur.
⚫ To achieve the optimum life for the battery, operating discharges of more than 80% of
the rated capacity (deep discharge) and long-time big current discharge should be
avoided.
⚫ If PE separators are used in the battery, it is normal to appear oily substance during
usage.
⚫ It is needed to charge within 24 hours after the using of the battery, and the charging
should be adequate, but not overcharge, otherwise, the battery life will be shortened.
This also applies to partially discharged batteries.
⚫ During charging, the temperature limit of the electrolyte is 55℃, if the temperature is
close to 55℃, Need find ways to cool down or change to a smaller charging current, if
the temperature keep close to 55℃, stop the charging temporarily, and charge again
when the temperature is lowered down.
⚫ A battery temperature of 30℃ is specified as the rated temperature. Higher
temperatures shorten the life of the battery, lower temperatures reduce the available
capacity. 45℃ is the upper temperature limit and is not acceptable as an operating
temperature.
⚫ Regularly check whether the wire connection is loose or not, replace it if necessary.
⚫ For initial cells, check and record density and levels of electrolyte, and need regularly
check the density and the levels, add distilled water if necessary, otherwise, the service
life of battery will be shortened.
⚫ Press and collision is forbidden during the check and test of the cells.
⚫ Normal used cells charged by constant current should be equalizing charged per two
months, Normal used cells charged by intelligent charger should be equalizing charged
per half month。

2. Place the cells into use

2.1 Preparation for use
Remove dirt from the top of the cells, inspect for the physical damage one by one before
placing the cells into use. If there is any damage, the cells should be repaired or changed.
After the inspection and making sure, the cells can be connected according to the
requirement.

CAUTION!
Batteries and cells are heavy! Ensure secure installation! Use only suitable handling
equipment e.g. lifting gear in accordance with VDI 3616.

The specified torque loading for the screws of the charger cables and connectors
are:
steel
M10 23±1 Nm

2.2 Preparation for the electrolyte

2.2.1 The rated specific gravity of the electrolyte is related to a temperature of 30℃,and the
nominal electrolyte level in the cell in fully charged condition. Higher temperatures reduce
the specified gravity of the electrolyte, lower temperatures increase it. The temperature
correction factor is -0.0007 kg/l per ℃.

The electrolyte must conform to the purity regulations in DIN 43530 part 2.

Refilling water must conform in quality to DIN 43530 part 4.

Prepare the electrolyte according to the electrolyte density data in fully charged condition
specified in the following table, and the water and sulfuric acid composition ratio should be
also according to the data in the following table:
No Electrolyte density Electrolyte density water and sulfuric acid
In fully charged condition which should be prepared （Density:1.835 g/cm³）
(g/cm³)(30℃) (g/cm³)(30℃) volume ratio mass ratio
1 1.27±0.005 1.245±0.005 3.23:1 1.75:1
2 1.28±0.005 1.255±0.005 3.1:1 1.7:1
3 1.29±0.005 1.265±0.005 3.6:1 1.65:1

CAUTION!
When working on batteries! Use protective glasses and clothes - face, foot, hand protection
and PVC or rubber apron. Rubber gloves should be used when working directly with the acid.
Droplets or mist of acid will destroy many materials used for clothing. This is often not
observed until the clothes are washed.

2.2.2 The container used for mixing electrolyte should be acid proof heat-resisting and clean.
First pour certain amount of water into a heat and acid-resistant container slowly in the
proportion volume and stir the mixture at the same time so the sulfuric acid doesn't settle on
the bottom.

CAUTION!
Always pour acid into water, never pour water into acid because a dangerous violent
chemical reaction can occur. Temperature will increase immediately and acid will splash.

3 Charging
The user can charge the battery by constant current or by intelligent charger, Charge the
battery by constant current for initial charge.

CAUTION!
The delivered battery has been initial charged before leaving factory, The following
initial charge content is mainly the instruction for cell service, especially when the
electrolyte has been replaced completely.

For cells which is without initial charge

3.1.1 Remove the vent cap and sealing tap, add electrolyte into cells, the electrolyte level
shall be 15~20mm above the separator guard; for the cells with water auto filling system, the
level shall be 28~30mm above the separator guard. After stand for 3~4hs, the cells should
be initially charged if the temperature of the electrolyte is lower than 35℃, if the temperature
of the electrolyte is higher than 35℃, the cells should be cooled first before initial charging.

CAUTION!
The intervals between adding electrolyte to initial charge should not exceed 12 hours.
3.1.2 Check the polarity of the cell one by one with DC voltmeter to avoid reverse charging
and damage. Otherwise battery and charger could be destroyed.
3.1.3 Charge the cells with DC power source. Connect the cells to the charger always
positive (+) to positive and negative (-) to negative terminals. The charger voltage
should be 3 times of the voltage of all cells in series.

CAUTION!
The battery end cables must have a good contact to terminals, check that the polarity is
correct (positive to positive, negative to negative). Otherwise battery and charger could be
destroyed.
3.1.4 After confirming above preparation work carried out, the initial charge can start. The
whole charge process will be divided to two stages:
Stage I: As the charge progresses, the voltage increases until it reaches approximately
2.40V.
Stage II: Continuously charge the cells in the second stage mode till electrolyte gassing
violent and the specific gravity and cell voltage reach and remain their constant
values over a three-hour period and the charge volume reach 3.5 times of the rated
capacity.

CAUTION!
During charging, the temperature limit of the electrolyte is 55℃, if the temperature is close to
55℃, Need find ways to cool down or change to a smaller charging current, if the
temperature keep close to 55℃, stop the charging temporarily, and charge again when the
temperature is lowered down.

The adjustment of the specific gravity and level of the electrolyte, If the specific gravity
is lower than normal, remove a part of electrolyte from the cell, slowly add sulfuric acid with
1.400g/cm3 specific gravity, wait 15~20 minutes for the added acid to become thoroughly
mixed, then read the specific gravity, if it still low, repeat the progress until gravity is normal.
If the specific gravity is higher than normal, withdraw from the cell a small amount of
electrolyte and replace with approved water. Repeat, if necessary, at 20-30 minute intervals
until the desired reading is obtained.

3.1.5 After the adjustment of the specific gravity and level of the electrolyte, then
continue to charge for about 1h for the electrolyte become even, the initial charge is finished.
Close the vent cap, clean the top surface, place the cell in service.

IMPORTANT!
For initial cells, check and record density and levels of electrolyte.
Check connections between cells. If there's any abnormal phenomena, contact with the
service department of your dealer immediately.

3.2 Normal charge

After the initial charge, the cells operated under normal conditions should be recharged in
normal charge mode. The normal charge method is just like the initial charge, and the
normal charge parameters are stipulated in table 1, the charge volume is about 1.2 times of
last discharge volume. For new cells, the charge volume should be 1.5 times of the last
discharge volume for the first 5 cycles.

3.3 Compensation charge

The compensation charge method is like second stage current in normal charge. The
density of electrolyte and terminal voltage should stay 2~3hs. The interval of compensation
charge should be no less than 30 days.

3.4 Equalizing charge

3.4.1 The aim for equalizing charge
While the cells are using, because short charge, untimely charge after discharge, the activity
material can’t be recovered, this can effect cell's life. Different conditions between cells in
series because long term use, this can also effect cell's life. Equalizing charge can avoid
sulfate phenomenon, lengthen cells' life.
3.4.2 An equalizing charge should be conducted under the following conditions:
a.) Discharge voltage is often lower than final voltage.
b.) Discharge current is often higher than normal.
c.) Discharge cells are not often charged in time.
d.) Any slight harmful impurities enter into the cells.
e.) Cells are often charged weakly or stored foe long time.
f.) Remove the cell group for checking and clean the sediment.
g.) Normal used cells charged by constant current should be charged per two months,
Normal used cells charged by intelligent charger should be charged per half month.

3.4.2 Method of equalizing charge

A: Constant current charger
First, the cells should be charged in normal mode. When normal charge finish, after stand for
about 1h, then charge the cells with the current of the second stage of the normal charge to
violent gassing, stop for 1h. Repeat for several times to the voltage and specific gravity of
electrolyte should be corrected to the specified value.
B: Intelligent charger
Carry out the equalizing charge according to the instructions in the manual of the intelligent
charger.
Normal used cells charged by constant current should be charged per two months, Normal
used cells charged by intelligent charger should be charged per half month.

3.5 Requirement of charge measure record

Measure and record the voltage, density of the electrolyte and temperature of the cell before
charge. Record the voltage of the cell after start charge. The interval of measure voltage is
4h during charging. Measure and record voltage, density and temperature of each cell
during equalizing charge, the interval is 2h. Measure voltage, density and temperature,
adjust the density of electrolyte and liquid level after charge.

4 Maintenance and precautions

4.1 The cells should avoid short charging, overcharging, over-discharging, violent charging,
otherwise the service life will be shorten.
4.1.1 Insufficient charging
Insufficient charging will cause permanent sulphation because the temporary sulphate is not
completely removed from the plates during recharge allowing the remainder to convert to
permanent sulphate, the rated capacity and service life will be relatively reduced.
1.1.2 Overcharging :
overcharging is charging beyond the time necessary to fully charge the battery or charging
at too high a current for the particular battery. It causes corrosion of the positive grids
causing them to fracture and reducing their ability to carry the starting current. Overcharging
is usually accompanied by heavy gassing which dislodges active material from the positive
plates. This then deposits in the bottom of the container and can lead to short circuiting
between the plates. Overcharging also results in high temperatures which leads to rapid
deterioration of the plates and separators. Buckling of the plates may also occur. This can
result in perforation of the separators and internal short circuits.
4.1.3 Over discharging
To achieve the optimum life for the battery, operating discharges of more than 80% of the
rated capacity should be avoided (over discharge). When these batteries are recharged,
excess heat is generated due to the high resistance of the paste (lead sulphate) which can
result in damage to the plates and separators.

4.2 Make certain the charging workshop has perfect ventilation facilities. There is hydrogen
while charging. Adequate ventilation will make the explosive mixture of gases loses its
flammability.

4.3. The temperature shouldn't be higher than 55℃. Otherwise, there will be hydrogen
release and reduce the contact between activity material and grid, enhance the electrolyte's
corrosion to the plate, aging the rubber washer in advance, influence the life cycle of the
cells.

CAUTION!
The temperature shouldn't be higher than 55℃.Otherwise, aging the rubber washer in
advance, influence the life cycle of the cells.

4.4. Make certain that surface of cell, connectors and bolts are cleaning and dry. Using a
solution of baking soda and water to clean the acid that may be collected on cell, then clean
the cell with clear water dry it. Be sure, there is no solution enters the cell during cleaning.

4.5.The cells should be equalizing charged by intelligent charger per half month.

4.6.Measure the voltage, density of the electrolyte, temperature of the cells no less than one
time one week. Measure and test the cell group's condition every month. The content is: if
the terminal connections are tight for protecting from damaging, the terminal and exploring, if
the level and density of the electrolyte is normal, if the voltage is equalized.

CAUTION!
Measure the voltage, density of the electrolyte, temperature of the cells no less than one
time one week. add distilled water If the level of the electrolyte is lowered, and only distiller
water is allowed to add.

4.7.Press and collision is forbidden during the test of the cells.

2. Troubleshooting
There are many reasons caused cells to breakdown. Except affections of manufacture
quality and transportation, wrong use and maintenance is one of the main reasons. Features
reasons and method are as following:

5.1 Internal short-circuit

5.1.1 Symptoms
The charge voltage is always lower than normal. Less or without gassing at the end of
charge. The temperature is high and raise faster during charge. The specific gravity of the
electrolyte raise slowly or without change. The discharge voltage quickly reduced to the final
voltage. The open-circuit voltage is seriously low. The self-discharge is serious.
5.1.2 Probable causes
The active materials are expanded or shed simultaneously the separators are damaged.
Plate is bending, and the separator is damaged simultaneous. Too much sediment. Some
conducting materials enter the cell.
5.1.3 Possible remedy
Change plate, adjust the bending plate, change the damaged separators, cleaning the
sediment, remove the conductor.

5.2 Sulfate of the plate

5.2.1 Features
Capacity of discharge is lower, density of the electrolyte is lower than normal. The initial and
final voltage is higher than normal cell during charge. It gassed earlier during charge, the
temperature of electrolyte raises quickly and is over 55℃. The voltage falls to final voltage
during discharge.
5.2.2 Probable causes
For long time short charge, untimely equalizing charge, overcharging, deep discharging, the
lower level of the electrolyte and other reasons, part of PbSO 4 in positive and negative
plates can't transform into active material during charging.
5.2.3 Possible remedy
Plate sulfate cells can overcharging to be recover, or charge with small current ,or pull out
water. To protect this phenomenon, cells should be operated by maintenance, pamphlet and
be equalize charged in time.

6.Cell service
6.1 Change electrolyte
6.1.1 Cut the cover-to-jar seal carefully, then remove the plates group out of the jar.
6.1.2 Measure the specific gravity of electrolyte, then pour out the electrolyte and wash out
the sediment.
6.1.3 Reinstall the plate group into jar, then heat seal the cover to jar.
6.1.4 Add electrolyte with the same specific gravity to the specified level.
6.1.5 Charge the cell and adjust density and level of the electrolyte.

6.2 Change jar

Pour out the electrolyte into the new jar, other steps follow above a, c, d, e. The time for
plates group exposed in air should be less than 0.5h to minimize the oxidization on the
negative plates. Or put plates into the water (specification for water is DIN 43530 part 4.). It
should be conducted after the discharge at 5h rate for analyzing and changing, the
electrolyte, changing the jar and raise out the plate group for inspection and cleaning the
sediment.

7.Transportation and storage

7.1 Cells, spare parts and tools should be packed in the packing boxes, the contact place
should be fixed.

7.2 If the level of electrolyte is lower than standard because of longtime transport and
hoisting, it's normal. If the reason is electrolyte spilled or the water evaporated, pull out
specific gravity of electrolyte or specific water to adjust the level during equalizing charge.

7.3 Cells' storage should fit requirement as follow:

7.3.1 For cells which leave factory without initial charge, it should be stored in clean and dry
rooms (the temperature should be 5~45℃). The storage time is 2 years from the day the
cells leave factory. If more than 2 years, the cells initial charge time should be lengthen.

7.3.2 For initial charge cells, it should be storage d in clean and dry rooms with good
ventilation (the temperature should be 5~45℃). If dust or electrolyte fall down on the cover
of the cell, use 5~10% of soda water to clean. The cells' appearance should be clean and dry.
Avoid direct sunlight, and heat source. Cells should be supplement charged by the current of
second stage of normal charge every month.

8. Points for attention

⚫ Check amount of cells and specifications of spare parts.
⚫ Check if there is any damage of every parts of cell and spare parts one by one.
⚫ For initial cells, check and record density and levels of electrolyte.
⚫ Check connections between cells.
⚫ If there's any abnormal phenomena, please tell us.

9. User's storage battery record

⚫ The date for receiving the cells.
⚫ Start and end time for storing and storing conditions, e.g. The ambient temperature and
relative humidity.
⚫ Start and end time for service.
⚫ Each charge record, especially the initial charge record.
⚫ Troubles during the service period and the remedies.
⚫ The operating conditions: discharge current, discharge time, temperature of the
electrolyte, ambient temperature and relative humidity.

10.Service items
⚫ Introduce the performance and use method of the products.
⚫ Train operators.
⚫ Charge and maintain ace the cells, solve quality problems of customers' in the use.
 Chapter 9 Warranty Policy

WARRANTY
POLICY AND PROCEDURES
Valid time: year 2012

Suzhou Pioneer Material Handling Equipment & Technology Co., Ltd (hereinafter
referred to as "Zowell ") maintains a liberal warranty program to insure ultimate
customer satisfaction in the event of component failure. This program covers all of
Zowell’s material handling equipment. The intent of this warranty manual is to set
forth policy, procedures and limits of the program, and to expedite the proper
handling of warranty claims. Your attention to the details of the program will assure
resolution of warranty claims with a minimum expenditure of time and effort.

GENERAL WARRANTY POLICY

Policy valid date: Jan/01/2012
Policy expire date: Dec/31/2012

Principles:
Zowell only provides warranty for equipment failure caused by original quality problem, and
only extend to the original purchaser.
Any warranty policy from Zowell is not available for but not limited to any of the following:
<1> The technical service information (TSI) hasn’t been completely filled in and sent to
[email protected] of Zowell aftersales service department to get authorization. If
you buy this equipment directly from our company, please fill in the technical service
information (TSI) by yourself, if you buy this equipment from our authorized dealer,
please let your dealer to fill in it.
<2> Equipment modified or design changed or parts replaced not approved by Zowell
<3> Equipment being used in improper environment, such as cold storage area (except
those with cold storage protection), overheating area, dusty area, moisture area, etc.
<4> Equipment damaged by improper storage / using or accident.
<5> Equipment used beyond rated capacity.
<6> Equipment hasn’t be provided by proper maintenance.
<7> Failure to follow operation manual instruction.
<8> Painting scratch caused by transportation pumping is not included in warranty policy,
should declare to the transportation company as soon as the equipment is unload, with
enough evidence.
<9> The phenomenon which do not affect the normal use of the equipment.
<10> The poor phenomenon caused by the misuse of the oil which is not specified in the
manual.
<11> Problem can be solved by adjustment and easy repair.
<12> The battery hasn’t be provided by proper maintenance, which cause the deep
discharging, low electrolyte level, short circuit of the battery pack, finally the life of the
battery pack is shortened.
<13> Any problem caused by force majeure, like war, floods, typhoon, fire, strikes, storm,
earthquake or other which can not be foreseen.

Limited Liability:

1. Zowell only offers warranty to the items listed in this Limited Warranty or in the warranty
terms listed in other relevant agreement or documents. All legal and implicit warranties
applicable to the products are definitely exempted, including but not limited to the
merchantability and applicability of all implicit warranties.

2. Zowell shall not be liable for the following customer losses, including but not limited to:
(1). Labor cost and expenses occurred during Customer repair;
(2). Losses caused by equipment failure;
(3). Cost for third party analysis such as metallurgical analysis or oil analysis etc;
(4). Profit loss, acquirable benefit loss, third party loss or any indirect loss.

3. Zowell does not approve or authorize any third party alterations, amendments or
changes to this Limited Warranty.

Zowell Warranty For Parts :

<1> Warranty is for parts only. See detail warranty parts and valid time under each
equipment warranty.
<2> Any warranty part is provided by Zowell as FOB Shanghai.

Warranty time start:

Start from the day firstly delivered from Zowell factory.

Warranty due to shipment:

If it is found that the equipment has been damaged in transportation, please do not return it
to us, but take necessary picture evidence and claim at once to the carrier, insurance
company if related,shipping company, post office or other transportation organization.
Failure to follow this procedure will result in refusal by the transportation organization to
honor any claims with a consequent loss to the receiver.

Warranty parts return:

<1> Please do not send defective parts back to Zowell unless you be requested to do.
<2> Certain defective parts must be returned with freight prepaid as precondition of getting
compensation parts free of charge, such as electric controllers which should not be
opened before return back，electric motor, charger, electric instrument, internal
combustion engine etc. In either case not returning or be opened, Zowell will invoice the
buyer according sales price of parts.
<3> Warranty part cost should be charged to the buyer if request defective parts not be sent
back to Zowell within 30days of the application date.
<4> You will still be charged by Zowell if the defective parts are determined to be damaged
by improper operation.

Changes and improvement:

Zowell is constantly striving to improve its products. Changes in design and improvement will
be made whenever the efficiency of its products is improved thereby, but without incurring
any obligation to incorporate such improvements in any products which have been shipped
or are in service.

Zowell Warranty Policy

Manual handling Equipment
WARRANTY TIME PERIODS
<1> 12 months: hydraulic pump, chassis, for all model manual pallet truck and other manual
equipments
<2> 6 months: axles for all model

Zowell Warranty Policy

Electric lift-manual Push handling Equipment
WARRANTY TIME PERIODS
<1> 12 months: chassis, frame, hydraulic pump, battery (only single cell of the battery can
be claimed).
<2> 6 months: axles.

Zowell Warranty Policy

Self Propelled Electric Warehouse Equipment
Note: the operating hour of the claim equipment must be provided (photo request).
WARRANTY TIME PERIODS
<1> 12 months or 1,000 hours whichever comes first. (UNITS EQUIPPED WITH
ELECTRONIC SPEED CONTROL ONLY):
Drive motor (except brushes), transmission, electronic speed controller, lift motors
(except brushes), pump, wiring harnesses, valves, oil seals, hydraulic hoses, hydraulic
cylinders, weldments, castings, battery (only single cell of the battery can be claimed).
<2> 90 days or 250 hours whichever comes first:
Motor brushes, contactors, switches, wheels, rollers, bearings, bushings, brakes, axles,
connectors and fasteners.

Zowell Warranty Policy

Forklift Trucks
Note: the operating hour of the claim equipment must be provided (photo request).
WARRANTY TIME PERIODS
<1> 12 months or 2,000 hours whichever comes first: the engine, transmission, torque
converter, rim, drive axle assembly, steer axle assembly, brake drum and hub assembly,
electronic system, chassis, or mast frame originally incorporated in the said Zowell
product, provided.
<2> 12 months or 1,000 hours whichever comes first: hydraulic pump, wheel brake
assembly, battery (only single cell of the battery can be claimed).
<3> However, as to the following parts, there’s no warranty period: parts and accessories of
engine, easy wear parts such as seals, hose, rollers, brake shoe, lamp, alarm, horn,
 beeper, fuse or hardware such as bolts, screw, washer, etc, unless problem is found
when first shipment received.

Any puzzle on this WARRANTY POLCIY will be explained only by Zowell.

Suzhou Pioneer Material Handling Equipment & Technology Co., Ltd

Jan.1st, 2012