Operation Manual

Lithium-ion battery

Original Instruction V1 11/2021

Preface

Thank you for buying our products.

The manual will show you the way of correctly using the battery as well as relevant preventive
maintenance and safety operation. The battery should be operated only by well-trained
professionals and by no means by non-working personnel. Operators are supposed to read through
the manual before actually operating the battery.

Explanations on the manual

With the continuous upgradation and improvement of our company’s products, you may find a
slight difference existing between your carrier and some introductions in the manual.

All the information, specifications and illustrations in the manual are effective in times of printing
and our company maintains the right to modify the specification (s) or design (s) of our products at
any time without any beforehand notification.
Safety signs and corresponding esplations

DANGER

Means that failure to comply can cause risk to life and/or major damage to property.
WARNING
Please strictly adhere to these safety instructions to avoid personal injury or major damage to
equipment.

CAUTION
Please pay attention to the important safety instructions.
i NOTE
Pay attention to Instruction.
Information on the conformity of lithium-ion batteries:
The manufacturer of the lithium-ion battery declares that: the lithium-ion battery
conforms with the provisions of the following EU directive 2014/30/EU in accordance with
EN12895.
These batteries has been certified according to EN 62619:2017 for safe use and according to
UN38.3 for safe transport.

Intended use
• Operational application temperature 0° C-40° C, humidity ＜ 80%;
• Charging application temperature 5° C-40° C;
• The battery's maximum operation altitude is up to 2000m;

i NOTE
Lithium-ion battery working temperature is divided into charging temperature requirement and
discharging temperature requirement:
The charging temperature range is 0°C-40°C. A high-rate recharging operation below 0°C may
lead to battery damage, so we recommend temperature range is 5°C-40°C;

The discharging temperature range is -20°C-55°C. If used in low temperature°C-20°C-0°C, battery

discharge capacity will be smaller compared with the one in normal temperature condition, which
is normal; battery used between 40°C-55°C in the long run will accelerate the aging of the internal
material. It may shorten the service life of battery, so not recommended. So we recommend
working temperature is 0°C-40°C.
Reasonably foreseeable misuse
• Never short circuit the battery terminals.
• Do not reverse the battery polarity.
• Do not overcharge.

Accessories
Do not use a charger that is not released by EP for lithium-ion battery.

BMS (Battery Management System)

The battery is permanently monitored by the BMS (Battery Management System).
This provides the communication with the truck.
The BMS continually monitors items such as the cell temperature, the voltage and the charge
status of the cells. It also functions as a safety cut-off device in case of overcharging, overcurrent,
or overheating.
It is necessary to respect the following guidelines:
• Read the documents provided with the lithium-ion battery carefully.
• The battery is not used at a loss of power. To ensure the battery life, should avoid thedischarge
depth of more than 80% of the rated capacity of the battery. Whether it is partiallydischarged or
fully discharged, the battery should be immediately charged.
• Lithium batteries have a special charger, may not be charged with other types of batterycharger,
so as not to charge lithium batteries
• The new factory battery should not be discharged, it must be fully charged before use.
• Do not open the lithium battery cover maintenance, lithium battery failure, timely contact with
• the manufacturer.
• Only trained and authorized personnel are permitted to charge, service and replace the batteries.
• Do not place lithium-ion batteries on or near flames or hot heat sources (> 65°C). This may cause
the batteries to overheat or burst into flames. This type of use also impairs the performance of
the batteries and reduces their service life.
• It is forbidden to take out the battery in the charging state.
• It is forbidden to use and store the battery at low power (the use and storage of power loss will
cause the early loss of battery system capacity and accelerate the service life of the battery
pack);
• It is forbidden for unqualified personnel to dismantle and overhaul the battery system and
supporting charger and other devices; the battery system is a dangerous product, and
maintenance and replacement can only be performed by professionals;
• Do not hit, throw or trample on the battery, do not heat the battery, do not throw the batteryinto
the water.
• Have class D fire extinguishers or inert gas, carbon dioxide, powder or foam fire extinguishers
near the zone in which the lithium-ion batteries are used.
• If the connection of the battery pole is found to be oxidized, wipe it with a dry cloth and polishit
with a fine sandpaper before use. Otherwise, it may cause poor contact and the functionfails.
• Prohibit the use of strong static electricity and strong magnetic field, otherwise easy todamage
the battery safety protection device, bringing security risks.
• Do not use this series of products with other models or types of batteries in series or inparallel;
prohibit the entire system with lithium-ion battery protection circuit board or battery management
system, the power system in series or in parallel operation, if necessary, please contact this
Company technical department to obtain the correct technical support.
• When charging and discharging Try to avoid splashing water or other conductive objects onthe
battery cover and pole, such as exposure to heavy rain.
• Once inadvertently make some kind of conductor come into contact with the positive and
negative poles of a single battery or battery pack at the same time to cause a short circuit, be
sure to disconnect the circuit which causes the short circuit in the shortest time.
• Extinguishing Media: Spray water or smoke or fire-burnt batteries in water. Use type D fire
extinguishers, CO2, dry chemical, or foam fire extinguishers.
• Risk of fire or smoke: LFP batteries can leak / evaporate or decompose and release flammable
electrolyte under the condition of 150 ℃ if they are improperly used or affected by the
environment. Hydrogen fluoride (HF) and phosphorus oxides may form during fire, and chemical
reactions between LIPF6 and water in the electrolyte will produce fluoride and carbon dioxide.
• Contact with eyes: Electrolyte inside the battery will cause eye irritation and inadvertent contact.
Please do not rub it. Rinse immediately with plenty of water for at least 15 minutes. If necessary,
please go to the hospital for treatment immediately. Otherwise it will hurt your eyes.
• Contact with skin: The electrolyte inside the battery may cause skin infections, inadvertent
contact, take off contaminated clothing and wash the infection with plenty of water and soap for
at least 15 minutes, do not rub the ointment.
• Inhalation: When the battery is leaked or ruptured, the internal components of the battery may
cause mucus, edema and other respiratory tract problems, inadvertently inhaled, to fresh air and
ventilated contaminated area. If necessary, oxygen or artificial respiration.
• Special Protection Tools: Use breathing apparatus to avoid inhalation of irritating gases. Wear
protective clothing or other devices to prevent body contact with the electrolyte.

DANGER
Failure to comply with these safety instructions can result in fire and explosion or the leakage
of harmful materials.

WARNING
Should such issues as failing to abide by the operation manual, failing to use the original parts
for maintenance or damaging caused by users themselves occur, the quality guarantee will be
invalid automatically!

Special lithium-ion safety rules

DANGER
• There is a risk of fire.
• Have class D fire extinguishers or inert gas, carbon dioxide, powder or foam fire
extinguishers near the zone in which the lithium-ion batteries are used.

DANGER
• Electrical danger
• Only the After-Sales Service Centre technicians can open the battery.
 Table of contents
Pg.
1.Lithium-ion battery Introduction................................................................................................. 1
2.Safety and warning.................................................................................................................... 3
3.Potential hazards....................................................................................................................... 4
3.1 Fire hazard............................................................................................................................. 5
3.2 Material discharge.................................................................................................................. 6
3.3 Touch voltage hazard.......................................................................................................... 6
3.4 Hazard of faulty or discarded battery.............................................................................. 6
4. Performance data for lithium-ion battery.................................................................................. 7
5. Battery indicator....................................................................................................................... 10
6.Nameplate................................................................................................................................. 12
7.Lithium-ion system safety test................................................................................................... 13
8.Charging.................................................................................................................................... 16
9.Transportation........................................................................................................................... 19
10.Use a hoist to lift the battery.................................................................................................... 20
11.Instructions for disposal........................................................................................................... 21
12.Storage.................................................................................................................................... 21
13.Common Problems and Solutions........................................................................................... 22
14.Maintenance............................................................................................................................ 23
1.Lithium-ion battery Introduction
The lithium-ion battery unit is composed of battery cells in series or in parallel; It is equipped with
battery management system for monitoring and protecting the lithium-ion battery; The different
or the same electrical connector design for charging and discharging; The truck's key switch can
control power supply of the battery; The circular meter shows data, error code, total voltage and
temperature, ect.

2.Safety and warning

• Abide by the operation manual!
• All the operations related to the battery must be implemented under the
instruction of professionals!

Always wear protective clothing (e.g. safety goggles and safety gloves) when
working on cells and batteries!

• No smoke and fire!

• Avoid the existence of open fire, fiery metal wire or sparks around the lithium-
ion battery, otherwise explosion or fire disaster may occur!

•Explosion or fire disaster is likely to occur; avoid short circuit!

•Keep the battery away from all fire sources, heat sources and flammable or
explosive materials!

•Don’t knock over the battery!

•Using lifting and delivery devices as specified. Prevent the battery cell, interface
and connection cable from being damaged by the lifting hook!
•If the materials leak out, do not inhale the fumes. Wear safety gloves!
•Always wash your hands after completing the work. Use only insulated tools.

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 •Dangerous voltage!
•Avoid hot plugging!
•Notice: the metal part of the battery cell is electrified, so don’t place any external
object or tool on the battery cell!

Do not place the battery on top of conductive objects!

•Don’t trample on the battery to prevent it from fierce shaking or shacking!

•Protect the battery from solar radiation or other forms of heat radiation.
•Do not expose the battery to any sources of heat.
+ -

•Do not physically alter the battery, strike, crush, compress, notch, dent or modify
it in any way.
•Do not open the battery, damage, penetrate, bend, heat or allow it to become
hot, do not throw it on the fire, short or immerse it in or wash it with water. Do not
drop it or allow anything to fall on it, do not store it or operate it in a microwave
oven, kiln or pressure vessel etc.

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3.Potential hazards
No hazards are anticipated if the equipment is used correctly.
Do not use the equipment for anything other than its intended purpose.
The following hazards can arise in the event of improper use:
Physical damage:
This can occur if a battery falls or is deformed through pressure (e.g. truck forks penetrate the
battery housing).
Mechanical damage includes cracks, breakage, splinters or holes in the battery housing. This
type of damage may be caused by a short circuit inside the battery,
which may result in harmful materials leaking, fire or battery explosion.
Short circuits:
These may be caused by connecting the two battery terminals (e.g. battery immersed in water)
Temperature effects:
High temperatures caused for example by sunlight or being store in warm locations (e.g. near
ovens) can result in harmful materials leaking, fire.
In order to avoid fire and leakage of harmful materials, a safe place for storing batteries must
satisfy the following criteria:
• Do not store in places often frequented by personnel.
• Do not store in places where valuable objects (e.g. cars) are stored.
• Fire extinguisher must be available to put out any fires.
• There should not be any fire or smoke detectors in the vicinity in order to ensure that an
automatic fire detection system is only activated in the event of actual danger (e.g. naked
flames).
• Small amounts of discharge from a single battery are not critical to the environment. Above-
average natural ventilation is required in this case.
• No ventilation intake pipes should be in the vicinity, as discharged content could spread
within a building.
Examples of where to store a non-functional battery:
• Roofed outdoor position.
• Ventilated container.
• Covered box with pressure and smoke discharge option.

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3.1 Fire hazard

WARNING
Physical damage, thermal effects or
incorrect storage in the event of a defect
can result in fire.
The battery materials can be flammable.

Particular hazard from combustion

products

WARNING
Contact with combustion products can be hazardous
Fires produce combustion products.
Combustion is a chemical process by which a flammable material combines with
oxygen under heat and light (fire).
The resulting combustion products can occur in the form of smoke, through leaking
fluids, escaping gases, debris as well decomposition products of certain chemicals.
These combustion products are substances that enter the body through the
respiratory tract and / or the skin, where they can produce and adverse effects such
as choking.
Avoid contact with combustion products.
Use protective equipment.
– Hydrogen fluoride (HF) Hydrofluoric acid = extremely corrosive
– Risk of toxic substances produced by pyrolysis
– Risk of highly flammable gas mixtures.
– Other combustion products: Carbon monoxide & -dioxide, manganese, nickel and
cobalt oxides.

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3.2 Material discharge

Battery electrolyte fluid can be hazardous

• Electrolyte fluid can be discharged if the battery is physically damaged. Electrolytefluid is harmful
and must not come into contact with the skin or eyes.
• If it does, rinse the affected parts with plenty of water and seek medical assistance immediately.
• In the event of skin irritation or if any substances are breathed in, seek medical assistance
immediately.
• In the event of inhalation bring the affected person into the fresh air and keep them still.
Precautionary measures for personnel
• Keep personnel away and facing the wind.
• Block off the affected area.
• Ensure there is adequate ventilation.
• Wear personal protective equipment.
• If vapours / dust / aerosols are present, use self-contained breathing apparatus.

Precautionary measures for the environment

Do not allow spilled fluids to enter the water system, drainage system or the underground water.

Cleaning measures
The leaked fluid must be removed professionally by the operating company on the
basis of a risk assessment and disposed of in the correct manner. The fire brigade,
the Agency for Technical Relief or similar institutions must be used. Absorb residues
with liquid-absorbent material (such as vermiculite, sand, universal binders and
pebble grain).

3.3 Touch voltage hazard

WARNING
Hazardous contact voltages only arise in
the event of a technical or physical defect.
The batteries are normally charged. There
is still some residual voltage in a
discharged battery. This must be
considered as a hazardous contact
voltage.

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3.4 Hazard of faulty or discarded battery
Please monitor the battery status when in use and in storage. If you find any broken batteries,
electrolyte leakage, abnormal expansion or pungent odors due to shipping damage or abnormal
vibration, please stop use immediately and keep at least a 5 meter perimeter around the effected
batteries. Please dispose of the damaged batteries properly and contact a recycling company to
recycle the batteries. For batteries that are under EP warranty policy, EP will access the warranty
claim according to your submission of the battery nameplate photo .
During the period waiting for disposal or recycle, please stock damaged and old batteries carefully
by following instructions:
1.Damaged and discarded battery temporary storage needs to be placed in an iron or plastic
container with water that can cover whole battery at least 5 days (The battery may emit smoke
when immersed in water. This is the process of consuming energy by the leaking battery, which is
a normal reaction).
2.For big battery with inner and outer boxes structure, Keep the batteries outdoors at least 5 days.
and contact a recycling company to recycle the batteries.
3.Keep the container and batteries outdoors and 5 meters away from other things, especially
flammable items.
4.Use protective gloves when putting batteries in or out of water.
5.Do not stack damaged or old batteries.

WARNING
1. Do not store the battery for a long time;
2. No load bearing, squeezing and contact stacking when storing the batteries;
3. Do not place the batteries near cargo warehouses or near flammable and explosive dangerous
goods.

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4. Performance data for lithium-ion battery
Battery nominal data
Battery cell
1 Cell material LFP
Battery system
2 Burst mode parallel circuit or series circui
3 Ambient relative humidity ≤80%RH
Operational application
4 0-40℃
temperature

BMS nominal data

BMS management system function
No. Item Function Function description
Monomer voltage Accurate acquisition of all cell voltage
1
detection data
Total voltage Accurate acquisition of total voltage
2
detection data
Temperature Accurate detection of battery
3
collecting temperature
Inspection/ Accurate detection of charge-discharge
4 estimates Current inspection
currents
Hall sensor is used to obtain the input
and output current of the battery, and
5 SOC Estimate the SOC estimation of the battery is
carried out by the method of Ampere-
time integration
Communication CAN
6 Communication and Debugging
function communication
Short-circuit Power circuit short circuit, contractor
7
protection disconnect
Over current Over current occurs, contractor
8
protection disconnect
Protection Over charging Over charge occurs, contractor
9
function protection disconnect
Over discharging Over discharge occurs, contractor
10
protection disconnect
Over temperature Over temperature occurs, contractor
11
protection disconnect
Sleep awakening charge communication wake-up,
12 Sleep wake
function battery switch button wake-up

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5. Battery indicator

No. Name Description

When all 10 cells are on, it indicates that the battery is full;
When the first cell and the second flash alternately, it indicates that the
1 Energy display battery is low and must be charged.
The battery remaining charge is displayed; “100%” indicates that the
battery is fully charged.
2 Total voltage The sum of the total voltages of the lithium battery series

3 Temperature Battery temperature

4 Charging current Current value when charging the lithium battery

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No. Name Description

5 Maximum cell voltage Maximum value of cell voltage

6 No. of cell Identification No. of the cell with maximum voltage.

7 Minimum cell voltage Minimum value of cell voltage

8 Cell No. of minimum cell voltage Identification No. of the cell with minimum voltage.

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6.Nameplate
Item Description
1 Battery Model
2 Nominal Voltage
3 Nominal Energy Li-ion Battery System
1 Battery Model Cell Type 6
4 Battery weight
2 Nominal Voltage Nominal Capacity 7
5 Serial No.
3 Nominal Energy Version No. 8
6 Cell Type
9
4 Battery weight Date
7 Nominal Capacity
5 Serial No.
8 Version No.
9 Date

Maintenance instructions
• Must be charged when remaining charge is
lower than 20％，avoid over-discharging or
over-charging.
• Remaining charge should be higher than 60
％ during short period of storage.
• Running the truck is strictly prohibited when
in the case of short circuit, low voltage or high
temperature.
• Perform charging, discharging test and
battery status inspection an least one time
every month,including total voltage, unit
voltage,voltage difference, temperature,
temperature difference, value of insulation
resistance,remaining charge, etc.
• Handle gently.do not throw,roll or collide.

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7.Lithium-ion system safety test
The following tests shall be carried out in a device with forced exhaust conditions and explosion-
proof measures.
Test item Test procedure Requirement

Altitude simulation Test cells and batteries Cells and batteries meet this requirement if there is
shall be stored at a no mass loss, no leakage, no venting, no
pressure of 11.6 kPa or disassembly, no rupture and no fire and if the
less for at least six hours open circuit voltage of each test cell or battery
at ambient temperature after testing is not less than 90% of its voltage
(20 ± 5 °C). immediately prior to this procedure.
Short-circuit test After charging the battery Cells and batteries meet this requirement if there is
system standardly, no mass loss, no leakage, no venting, no
place it in an explosion- disassembly, no rupture and no fire and if the
proof box, and short- open circuit voltage of each test cell or battery
circuit the positive and after testing is not less than 90% of its voltage
negative poles of a immediately prior to this procedure.
certain cell of the battery
pack with a wire with
an internal resistance
of less than 50mΩ. The
surface temperature of
the battery is recorded
during the test, and the
short-circuit lasts for 10
minutes.
Over-charge test After charging the battery Cells and batteries meet this requirement if there is
system standardly, no mass loss, no leakage, no venting, no
use a constant current disassembly, no rupture and no fire and if the
source to charge a open circuit voltage of each test cell or battery
single cell of the battery after testing is not less than 90% of its voltage
pack with 1C constant immediately prior to this procedure.
current until the voltage
reaches 1.5 times the
charge termination
voltage specified in the
technical conditions of
the enterprise or the
charging time reaches
1h, then stop charging.

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Test item Test procedure Requirement
Over- After standard charging, discharge the cell Cells and batteries meet this requirement
discharge with 1C current for 90 min and observe for if there is no mass loss, no leakage, no
test 1 hour. venting, no disassembly, no rupture and
no fire and if the open circuit voltage of
each test cell or battery after testing is not
less than 90% of its voltage immediately
prior to this procedure.
Vibration Cells and batteries are firmly secured Cells and batteries meet this requirement
test to the platform of the vibration machine if there is no mass loss, no leakage, no
without venting, no
distorting the cells in such a manner as disassembly, no rupture and no fire and if
to faithfully transmit the vibration. The the open circuit voltage of each test cell
vibration shall be a sinusoidal or battery after testing is not less than
waveform with a logarithmic sweep 90% of its voltage immediately prior to
between 7 Hz and 200 Hz and back to 7 this procedure.
Hz traversed in 15 minutes.
This cycle shall be repeated 12 times for a
total of 3 hours for each of three mutually
perpendicular mounting
positions of the cell. One of the directions
of vibration must be perpendicular to the
terminal face.
Drop test After the standard charge, the positive and Cells and batteries meet this requirement
negative terminals fall down from a height if there is no mass loss, no leakage, no
of 1.5m to the cement floor freely and venting, no disassembly, no rupture and
observe for one hour. no fire and if the open circuit voltage of
each test cell or battery after testing is not
less than 90% of its voltage immediately
prior to this procedure.
cells and large batteries shall be subjected Cells and batteries meet this requirement
Shock test to a half-sine shock of peak if there is no mass loss, no leakage, no
acceleration of 50 gn and pulse duration venting, no disassembly, no rupture and
of 11 milliseconds. Each cell or battery is no fire and if the open circuit voltage of
subjected to three shocks each test cell or battery after testing is not
in the positive direction followed by three less than 90% of its voltage immediately
shocks in the negative direction of each of prior to this procedure.
three mutually
perpendicular mounting positions of the
cell for a total of 18 shocks.

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Test item Test procedure Requirement

Impact A cylindrical or prismatic cell is to be Cells and component cells meet this
test impacted with its longitudinal axis parallel requirement if their external temperature
to the flat does not exceed 170 °C and there is no
surface and perpendicular to the disassembly and no fire within six hours of
longitudinal axis of the 15.8 mm diameter this test.
curved surface lying across the
centre of the test sample. A prismatic cell
is also to be rotated 90 degrees around
its longitudinal axis so that
both the wide and narrow sides will be
subjected to the impact. Each sample is
to be subjected to only a
single impact. Separate samples are to
be used for each impact.
Thermal Test cells and batteries are to be stored Cells and batteries meet this requirement
test for at least six hours at a test temperature if there is no mass loss, no leakage, no
equal to venting, no
75 ± 2 °C, followed by storage for at least disassembly, no rupture and no fire and if
six hours at a test temperature equal to the open circuit voltage of each test cell
–40 ± 2 °C. The maximum or battery after testing is not less than
time interval between test temperature 90% of its voltage immediately prior to this
extremes is 30 minutes. This procedure is procedure. The requirement relating to
to be repeated 10 times, voltage is not applicable to test cells and
after which all test cells and batteries batteries at fully discharged states.
are to be stored for 24 hours at ambient
temperature (20 ± 5 °C). For
large cells and batteries the duration
of exposure to the test temperature
extremes should be at least 12 hours.

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8.Charging
Always designate a specific area for the purpose of charging lithium-ion batteries. When
charging, make sure the battery charger is turned OFF before connecting the battery charging
cables. Lithium-ion batteries allow for fast charging, if the battery does not charge completely
in a normal period or if the battery management system (BMS) indicates a fault, then remove
the battery from service.EP recommends to opportunity charge lithium-ion batteries.
This is when the battery is recharged for short intervals during a shift period. It reduces or
eliminates the need for long charging periods, changing batteries during a shift, and extending
shift periods.

CAUTION
• No metal objects should be placed on the battery.
• Be careful of short-circuiting the battery! The battery should be filled up with distilled water
after charging.
• Charging in non-charging area is prohibited;
• No modification of the lithium-ion battery connector;
• Do not use irregular charging sockets;
• The net height of the charging area shall be higher than 5m, and the safe distance from
other areas shall be greater than 5m.
• The necessary extinguisher (yellow sand and powder fire extinguisher) should be equipped
around the charger so that emergency extinguishing can be carried out under extreme
conditions.
• Do not modify or disassemble the charging port and charging equipment, which may result
in charging failure and fire.
• After the charging is finished, do not disconnect the charging device when it is wet or
standing in the water, as this may cause electric shock and cause personal injury.
• Provide adequate ventilation during charging. To avoid damage to charger cord plug and
receptacle, do not pull on charger cord plug. Do not twist, rock or bend plug sideways.
Do not use if plug or receptacle is damaged. Loose or feels hot otherwise fire, property
damage or personal injury may result.
• Connect only properly grounded AC outlet. Do not touch uninsulated protion of output
connector or uninsulated battery terminal. Never try to change a frozen battery. There’s
the danger of explosion! Maintenance and repair must only be carried out by a qualified
specialist who is familiar with the dangers involved and aware of relevance regulations.

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Charging the battery
Cut off the power of the whole
truck and connect the charger

Battery system and circuit

maintenance

Inspect whether the

circular meter(3) is lit N Disconnect battery
charger cord

Battery charging

circular meter(3) N
If the power is below 90%,
shows 100%? replace the charger and fix the
battery system.

Finish charging and disconnect

the charger connector

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 Discharging the battery

Turn on the power of the vehicle

and press the wake-up button

Battery system and circuit

maintenance

Inspect whether the N Turn off the wake-up

circular meter is lit? button

Battery system normally

powered

Whether to meet the N

protection conditions?

The battery system is out of

power

Turn off the wake-up button and

charge the battery immediately

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9.Transportation
Before transporting any lithium-ion battery, check the current regulations on the transport
of dangerous goods. Comply with these when preparing the packaging and transport. Train
authorised staff to dispatch lithium-ion batteries.

NOTE
It is recommended that the original packaging is kept for any subsequent dispatch.
A lithium-ion battery is a special product.
Special precautions should be taken when:
• Transporting a truck equipped with alithium-ion battery
• Transporting only the lithium battery
A class 9 danger label must be affixed to the packaging for transport.
It is different if the battery is transported on its own or in a truck. An example of a label
appears in this supplement(see figure below). Refer to the latest current regulations before
dispatch as the information might have changed since this supplement was written.
Special documents must be sent with the battery. Refer to the applicable standards or
regulations.

For UN3480 Lithium-ion Batteries

For UN3481 Lithium-ion Batteries packed with Equipment

or Lithium batteries built into Equipment

Fig0000-00080OM

WARNING
Do not pack higher than 1.2 m above the floor of the container and secure properly.

i NOTE
"Overpack" is the name for the outer packaging of the dangerous goods.

i NOTE
Recharge the lithium-ion battery before transporting it taking account of the transport mode
(boat, road). Excessive discharge on arrival could damage the performance of the
battery.
Shipping faulty batteries
To transport these faulty lithium-ion batteries, contact the manufacturer's customer service
department. Faulty lithium-ion batteries must not be transported independently.

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10.Use a hoist to lift the battery
When moving, installing, or removing the battery, do the following:
• Ensure the service area is equipped with the proper tools designed for moving
industrial batteries, such as a conveyor or overhead hoist.
• Use lifting hooks that have safety latches and are the correct size.
• Use a specialized attachment device, such as an insulted spreader bar, to install the
lifting device to the battery. The width of the spreader bar must be the same as the
width of the battery, to prevent damage to the battery.
• Chain hoists must be equipped with containers to accumulate any excess lifting chain.
• Keep all tools and other metal objects away from the battery terminals.
• Only authorized personnel familiar with handling industrial batteries move, store,
install, or remove the battery.
• Use insulated tools and lifting equipment only.
• If installing a new battery, check the battery for damage before installing.

WARNING
Always use an appropriate lifting device and proper attachment to handle the battery.

DANGER
Ensure that no one is in the working range of the hoist when using it to lift the battery!
Walking around under the lifted battery is absolutely prohibited.

CAUTION
Use lifting equipment and a hoist that has sufficient carrying capacity to lift the batttery. For
the batttery weight , see section nameplate data for lithium-ion battery.
The sling must be fastened at the designated lifting points(handle) when using the hoist.

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11.Instructions for disposal
• Lithium ion batteries must be disposed of in accordance with the relevant environmental
protection regulations.
• Used cells and batteries are recyclable economic goods. In accordance with the mark
showing a crossed rubbish bin, these batteries may not be disposed of as domestic waste.
Return and / or recycling must be ensured as required by the
• Batteries Legislation.
• The method of battery recovery and reuse can be discussed with our company.
• We reserve the right to change the technology.

The requirements of recycling

1、Only authorized EP dealers who have attended the after sales training, are authorized to do
repairs on EP batteries.
2、All Li-ion battery should be placed in safe place according to the EP Li-ion battery Manual;
3、The transport of Li-ion battery must meet local regulation, EP will supply UN38.3 and MSDS
files according with UN and ADR regulation;
4、The package of Li-ion battery before delivery must meet the UN 3480 or local carrier regulation;

12.Storage
Before a long period of inactivity, the battery must be fully charged.
• We recommend that batteries are stored at a height between 60 and 120 cm. EP
recommends storing lithium-ion batteries in a raised rack or shelf that allows for protection
from possible collision damage.
• Store the battery in a dry place at a temperaturebetween 0 and 40° and a maximum humidity
of 85%. Lithium-ion batteries should be stored indoors, away from heat sources and direct
sunlight, and in a well-ventilated;
• When storing a battery for an extended period, inspect it regularly (every 2 to 3 months) and
maintain a charge level of 50% or greater.

CAUTION
Discharge can damage the battery
If the battery is not used for a long period of time, it can become damaged through discharge.

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 WARNING
1. Dispose of used batteries in time;
2. Do not store used batteries for a long time.
3. No load bearing, squeezing and contact stacking when storing batteries;
4. Do not place batteries near cargo warehouses or near flammable and explosive dangerous
goods.

13.Common Problems and Solutions

During the use and maintenance of the lithium-ion battery, the battery or battery system may
have one or more of the following abnormal conditions, please organize the professional
engineers and technicians to perform the necessary processing according to the instructions in
this manual; if you have any questions about the status or solutions, please contact ep dealer
or after-sales service department of the company to obtain professional technical support.
• If the battery is found to have abnormal mechanical characteristics such as swelling, cracked
casing, melted casing, and distortion of the casing before and during installation, stop using
the battery immediately, place it in open and well-ventilated space, and contact the after-
sales service.
• If abnormalities such as looseness, cracks, cracks in the insulation layer, burn marks, etc.
of the battery's pole pressing bolts, conductive strips, main circuit wires and connectors are
found before and during the installation, stop using the battery immediately, check the reason
for analysis and give it a fix;
• If the polarity of the positive and negative terminals of the battery is found not match the
polarity identification before installation, please stop using the battery immediately and
contact the after-sales service department to replace the battery or obtain other solutions;
• If the battery is found to emit smoke , immediately stop using the battery, using fire sand and
explosion-proof box for burial and isolation,wearing respirator and fireproof gloves move the
battery to a safe area,notify the after-sales service department of the company for record and
obtain technical support;
• If the battery is found to fire, using fire extinguisher(eg.Carbon dioxide extinguisher,Metal
fire extinguisher (PM 12i extinguisher),Metal fire extinguisher powder PL 9/78 DIN/EN 3SP-
44/95, Dry sand).

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14.Service
Lithium-ion batteries typically require no maintenance. If needed, any service or maintenance
should be performed by a certified technician. EP recommends that the battery be
inspected annually by a certified technician familiar with industrial lithium-ion batteries. Record
all battery service, maintenance, and inspections to maximize the service life of your battery
and lift truck.
Daily Maintenance
• It is necessary to arrange professionals for care during the charging operation, especially
when the battery is almost fully charged; make sure that the plug and the socket are in good
contact during the charging process to ensure the normal work of the charging device and
good contact of the connection points of the battery pack. If an abnormality occurs, the battery
needs to be repaired before charging;
• Check the battery voltage, temperature, voltage difference, etc. displayed on the circular
display meter before charging and discharging to ensure that all values are within the normal
range;
• If there is a large amount of dust, metal shavings or other debris on the upper cover and poles
of the battery pack, use compressed air or wet cloth to clean it in time, avoid cleaning with
water or water-soaked objects;
• When charging and discharging, try to avoid water or other conductive liquids splashing on the
top cover and poles of the battery, such as rainwater;
• Estimate the charging time and discharging time of the battery according to the actual status
of use of the battery or battery pack, observe whether there is any abnormality in the battery or
battery pack at the end of charging and the end of discharging, such as the voltage difference
of the battery.
• Perform a visual inspection of connector pins at the bottom of the battery for integrity,
deformation,ablation.

Regular Maintenance
• Check the nodes such as the conductive strips and voltage collection terminals for looseness,
shedding, rusting or deformation, etc., to ensure that the series-parallel harness used in the
battery pack is firm and reliable (once a month);
• Check the battery casing for cracks, deformation, loose poles, bulging and other abnormal
conditions (once a month);
• Check the reliability of the charging device to ensure that the charging device performs the
charging action in accordance with the voltage and current adjustment signals sent by the
BMS and to ensure that the battery will not be overcharged (once a month);
• Check discharge protection equipment, such as fast-acting fuses, AC contactors, relays, etc.,
to ensure that the battery pack can be quickly disconnected from the main circuit in the event
of a dangerous situation such as short circuit or over current (once a month);
• Check the insulation resistance between the battery pack and the vehicle body to ensure that
the resistance value meets the Chinese national standard (≥500Ω/V) and to ensure that there
is no electric leakage with the battery (once a month);
• We recommend chang the connector pins of lithium-ion battery every six month.

i NOTE
The components are maintenance-free, as a result there are no maintenance intervals
planned for this battery.

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No. Maintenance Method of operation Note Frequency
content
1 Check if the battery Perform a visual Make sure it tight weekly
connector and inspection,
communication Wear insulated gloves
connector and plug and shake it gently
are loose
2 Whether the Perform a visual Make the wiring harness weekly
external wiring inspection fixed well
harness has worn,
imprint, creases and
exposed line core

3 Check that the No dust, no water, no Clean surface if you found weekly
surface of lithium-ion corrosion, oxidation, dust, corrosion, oxidation,
battery looks clean rust, etc. rust by using dustless
cloth or air compressor
,water battery is strictly
prohibited to use
4 Check that the Torque wrench Reinforce screws weekly
outside screws of the correction requires no
battery are fastened loosening
5 Check if battery Check instrumentation Make sure the battery is weekly
capacity is too low SOC display not stored without charge
for a long time. If the
battery system needs to
be put on hold for a long
time, it is best to keep the
battery in half power state
and charge the battery
every 3 months to ensure
that the battery system is
in half power state.
6 Check if battery total Check instrumentation The total voltage shall not Everyday
voltage is normal display be higher or lower than
the requirements of the
operation manual

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No. Maintenance Method of operation Note Frequency
content
7 Check if battery Check instrumentation make sure the Everyday
temperature is display temperature meet with
normal operation manual

8 Check whether the Check instrumentation make sure the Everyday

highest string and display temperature meet with
the lowest string cell operation manual
voltage are the same

9 The battery pack Check instrumentation make sure battery pack Everyday
charge and display charge and discharge
discharge current current meet with
operation manual

10 Connector pins at Perform a visual If any ablation or Everyday

the bottom of the inspection deformation occurs in
battery daily inspection, the
battery connector pins
should be replaced in
time.

NOTE
The EP instrumentation is used for serviced.

Cleaning
The manufacturer recommends to only use compressed air at less than 207 kPa (30 psi) or a
slightly damp towel to clean the battery. The battery, or its charging station, may be equipped
with fans, heat sinks, or other cooling devices that require periodic cleaning. Always know and
follow the battery manufacturer's recommendations for cleaning and service.

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