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Battery Maintenance

2240 SRM 1

(77

F)

. See Figure 15. NEVER charge a battery at a

rate that will raise the electrolyte temperature above
49 C (120

F)

. Never let a battery stay discharged for

long periods.

Types of Battery Charges

1.

NORMAL CHARGE. This charge is usually
given to a battery that is discharged from nor-
mal operation. This is often an 8-hour charge.
Many customers charge the battery at regular
intervals that depend on use. This procedure will
keep the battery correctly charged if the battery
is not discharged below the limit. Always use a
hydrometer to check the battery if the battery is
charged at regular intervals. Frequent charging
of a battery that has a 2/3 or more charge can
decrease the life of the battery.

2.

EQUALIZING CHARGE. This charge is at a low
rate and balances the charge in all the cells. The
equalizing charge is usually given approximately
once a month. It is a charge at a slow rate for 3
to 6 hours in addition to the regular charging cy-
cle. Do not give an equalizing charge more than
once a week. The most accurate specific gravity
measurements for a charged battery will be after
an equalizing charge. If the specific gravity dif-
ference is more than 0.020 between cells of the
battery after an equalizing charge, there can be
a damaged cell. Consult your battery dealer.

NOTE:

Many customers have battery chargers that

can follow a program to automatically charge a
battery according to recommendations of the battery
manufacturer.

Use the recommendations of the

battery manufacturer for charging the battery.

The discharge limits and the limits for the specific
gravity before the battery must be charged again are
shown in Figure 17. NEVER discharge a battery be-
low the limits shown in Figure 18. Discharging a bat-
tery beyond the design limits will decrease the ser-
vice life of the battery.

NOTE:

Sometimes the capacity of a battery is not

enough to complete a work period. Check for the fol-
lowing conditions:
• The battery is too small for the job.
• The battery is not fully charged.
• The battery charger is not operating correctly.
• The battery is near the end of its service life.

Figure 17. Specific Gravity Versus Percent

Discharge

Figure 18. Specific Gravity Compared to

Charging Time

12

Summary of Contents for 2240 SRM 1

Page 1: ...INDUSTRIAL BATTERY ALL ELECTRIC LIFT TRUCKS PART NO 899648 2240 SRM 1...

Page 2: ...cifications of the original equipment manufacturer Make sure all nuts bolts snap rings and other fastening devices are removed before using force to remove parts Always fasten a DO NOT OPERATE tag to...

Page 3: ...Maintenance 6 Safety Procedures 6 Maintenance Records 7 New Battery 7 Cleaning Battery 7 Adding Water to Battery 9 Hydrometer 10 Battery Temperature 10 Charging Battery 11 Types of Battery Charges 12...

Page 4: ...THE QUALITY KEEPERS HYSTER APPROVED PARTS...

Page 5: ...tery converts chemical energy into electrical energy See Figure 1 Chemical changes within the battery give the electrical energy When the chemical reaction has occurred so the battery will not give it...

Page 6: ...d peroxide PbO3 for positive plates and sponge lead Pb for negative plates See Figure 3 A poten tial difference of approximately 2 volts per cell is generated The potential difference does not vary ac...

Page 7: ...life of the battery Maintenance free batteries use a calcium alloy of lead instead of an antimony alloy which reduces the amount of electrolysis In a maintenance free battery the amount of free stand...

Page 8: ...work periods per day is nor mally equal to the number of batteries needed For example for three work periods you need three bat teries The capacity of the battery you need is found as follows The size...

Page 9: ...e 24 volts 12 cell battery 36 volts 18 cell battery 48 volts 24 cell battery 72 volts 36 cell battery 80 volts 40 cell battery Battery as a Counterweight On electric lift trucks that use the battery a...

Page 10: ...a rating of 600 ampere hours and a 48 volt system use this formula 48 volts 600 amperes hours 1000 28 8 kWh The watt hours can be converted to kilowatt hours to indicate the battery needed for the op...

Page 11: ...ase Use the correct blocks or spacers to hold the battery in position in the lift truck Make sure the battery compartment is clean and dry All vent caps must be in position when the battery is in serv...

Page 12: ...Battery Maintenance 2240 SRM 1 Figure 10 Change the Battery Legend for Figure 10 1 INSULATED SPREADER BAR 2 INSULATED STRAPS Figure 11 Battery Inspection Report 8...

Page 13: ...MOST IMPOR TANT ITEM OF BATTERY MAINTENANCE See the instructions from the manufacturer of your battery for the operating level of the electrolyte Al ways use distilled water If you add distilled wate...

Page 14: ...corrections If the hy drometer you are using does not have a temperature correction you will have to use a thermometer Spe cial battery thermometers are available that will in dicate the correction fa...

Page 15: ...al area for charging batteries When charging the bat teries keep the vent caps clean The battery charger area must have ventilation so that explosive fumes are removed Open the hood over the battery o...

Page 16: ...ore than once a week The most accurate specific gravity measurements for a charged battery will be after an equalizing charge If the specific gravity dif ference is more than 0 020 between cells of th...

Page 17: ...ncreasing voltage across the resistor causes an increasing voltage at the battery terminals The charging is similar to the gradual charge The resistor must be correctly set or the charging rate will b...

Page 18: ...ry is fully charged the voltage level is constant 2 Remove a vent cap and look in the opening If you see bubbles in the electrolyte the battery is either fully charged or in the final stage of charg i...

Page 19: ...ES 2 SB CONNECTOR FOR POWER CABLES TO LIFT TRUCK 3 BRACKET 4 CONNECT AND DISCONNECT HANDLES BATTERY CARE 1 Keep batteries clean Remove any spilled elec trolyte 2 DO NOT overcharge the battery This act...

Page 20: ...K PINS ALIGNED AS SHOWN NO WIRE OR CONTACT IN HOUSING 5 SLOT FOR LOCK PIN 6 CONTACT FOR CONNECTOR OF 12 VOLT BATTERY TAP 7 KEY RED 2 AND BLACK 4 CONNECTORS ALIGN ON KEY 8 LOCK PINS FOR 12 VOLT CONNECT...

Page 21: ......

Page 22: ...TECHNICAL PUBLICATIONS 2240 SRM 1 2 08 6 07 1 06 11 03 3 03 2 02 3 00 9 96 5 96 2 94 1 83 7 78 Printed in U S A...

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