5.
Over Current / Shorts:
The pack is designed to
self-protect and shutdown if current exceeds
allowable rate. Batteries can be recovered by
removing short / over current condition /
operation, and waking up the pack again.
NOTE:
Only if
ALL
conditions above have been
performed and verified should the battery be serviced
and/or replaced.
Battery Ratings
The ratings of batteries are measured in ampere-hours
and kilowatt-hours at a constant rate of discharge.
Ampere-hours is the measurement of battery capacity.
The Lithium-Ion battery is rated at 56A/hrs. To
calculate ampere-hours, multiply amperes by hours.
See Table 5. For example, 5 amperes times 5 hours is
25 ampere-hours. You cannot change the potential
difference of a cell. The constant rate of discharging
can be compared to a measurement of the battery
capacity and ampere-hours. For example, a battery
with a rating of 600 ampere-hours during a work period
of 6 hours will generate 100 amperes per hour for 6
hours. The same battery cannot generate 300
amperes for 2 hours. The heat generated within the
battery will damage the battery.
Table 5. Battery Capacity Terms
Amperes × Hours = Ampere-Hours
600 Ampere Hours = 100 Amperes for 6 Hours
Volts × Amperes × Hours/1000 = Kilowatt-Hours
(KWH)
KILOWATT-HOURS
A kilowatt is 1000 watts. A watt is a measure of electric
power. The capacity in kilowatt-hours is the total power
generated by the battery. Watt-hours are measured by
multiplying the voltage by ampere-hours. To measure
the kilowatt-hours, divide the watt-hours by 1000.
volts × amperes × hours
= kilowatt-hours or kWh
1000
To calculate the kilowatt-hours for a battery that has a
rating of 600 ampere-hours and a 48-volt system, use
this formula:
48 volts × 600 amperes × hours
= 28.8 kWh
1000
The watt-hours can be converted to kilowatt-hours to
indicate the battery needed for the operation. Always
select the correct type of battery. Remember, a battery
that has a rating of 300 ampere-hours will not do the
same job as a battery that has a rating of 600 ampere-
hours.
Battery Maintenance
SAFETY PROCEDURES
1.
Lift batteries correctly with a crane or equipment
designed for the job. Move batteries with a lift
truck or a conveyor or rollers designed for that
purpose. If the battery does not have a cover, a
rubber mat or insulating material must be put over
the top of the battery to prevent a short circuit
with other equipment. Make sure the lifting
equipment has enough capacity for the job, such
as a chain sling.
2.
Never put metal materials or tools on a battery.
3.
Disconnect battery from lift truck before doing
maintenance or repairs.
4.
When maintenance on the battery or the battery
charger is required, disconnect both the AC and
DC power. If the battery connectors must be
replaced, make sure the positive and negative
terminals and cables are kept separate and
insulated from each other. Even a momentary
short circuit can cause an explosion and damage
the battery.
5.
When tightening the battery post nut, ensure
proper torque is used. Tighten battery post nut to
8.5 ± 1.5 N•m (6.0 ± 1.0 lbf ft).
2240 YRM 1890
Battery Ratings
15
Summary of Contents for 524150797
Page 1: ...Maintenance METRIC AND INCH SAE FASTENERS PART NO 524150797 8000 YRM 0231 ...
Page 4: ......
Page 8: ...Table 1 Bolts and Screws General 8000 YRM 0231 4 ...
Page 9: ...Table 2 Studs and Nuts 8000 YRM 0231 General 5 ...
Page 10: ...Table 3 Torque Nuts General 8000 YRM 0231 6 ...
Page 11: ...Table 4 Torque Nuts With Nylon Insert 8000 YRM 0231 General 7 ...
Page 20: ...NOTES 16 ...
Page 21: ......
Page 22: ...8000 YRM 0231 12 18 8 16 10 15 3 15 10 13 12 04 ...
Page 23: ...Maintenance INDUSTRIAL BATTERY PART NO 524158040 2240 YRM 0001 ...
Page 26: ......
Page 47: ......
Page 48: ...2240 YRM 0001 10 18 2 18 8 16 7 16 1 16 9 15 ...
Page 49: ...Maintenance AC MOTOR REPAIR MP20 A249 MPB045VG A245 PART NO 550036879 0620 YRM 1513 ...
Page 52: ......
Page 58: ...Figure 5 Traction Motor Repair A245 AC Motor Repair 0620 YRM 1513 6 ...
Page 62: ...NOTES 10 ...
Page 63: ......
Page 64: ...0620 YRM 1513 3 15 12 13 4 12 ...
Page 65: ...Maintenance MASTER DRIVE UNIT MP20 A249 MPB045VG A245 PART NO 550036880 0630 YRM 1503 ...
Page 68: ......
Page 75: ......
Page 76: ...0630 YRM 1503 3 15 12 13 4 12 ...
Page 77: ...Maintenance STEERING MECHANISM MP20 A249 MPB045VG A245 PART NO 550036881 1600 YRM 1504 ...
Page 80: ......
Page 83: ...Figure 2 Control Handle Assembly Lift Truck Models MP20 A249 1600 YRM 1504 Control Handle 3 ...
Page 86: ...Figure 4 Delivery Handle Optional Control Handle 1600 YRM 1504 6 ...
Page 91: ......
Page 92: ...1600 YRM 1504 12 18 11 17 7 16 3 15 12 13 4 12 ...
Page 93: ...Maintenance BRAKES MP20 A249 MPB045VG A245 PART NO 550036882 1800 YRM 1505 ...
Page 96: ......
Page 104: ...NOTES 8 ...
Page 105: ......
Page 106: ...1800 YRM 1505 3 15 12 13 4 12 ...
Page 107: ...Maintenance HYDRAULIC SYSTEM MP20 A249 MPB045VG A245 PART NO 550036883 1900 YRM 1506 ...
Page 110: ......
Page 117: ...Figure 4 Hydraulic Unit A249 1900 YRM 1506 Hydraulic Pump 7 ...
Page 127: ......
Page 128: ...1900 YRM 1506 2 15 12 13 4 12 ...
Page 129: ...Maintenance ELECTRICAL SYSTEM MP20 A249 MPB045VG A245 PART NO 550036885 2200 YRM 1508 ...
Page 163: ......
Page 164: ...2200 YRM 1508 6 18 11 16 10 16 8 16 4 15 12 14 ...
Page 165: ...Maintenance LIFTING MECHANISM MP20 A249 MPB045VG A245 PART NO 550036886 4000 YRM 1509 ...
Page 168: ......
Page 180: ...NOTES 12 ...
Page 181: ......
Page 186: ......
Page 192: ...NOTES 6 ...
Page 193: ......
Page 194: ...8000 YRM 1511 6 16 3 16 12 13 4 12 ...
Page 195: ...Maintenance DIAGRAMS MP20 A249 MP045VG A245 PART NO 550036889 8000 YRM 1512 ...
Page 198: ......
Page 201: ...Figure 1 Schematic Wiring Diagram Pallet Truck Sheet 2 of 3 8000 YRM 1512 General Notes 3 ...
Page 202: ...Figure 1 Schematic Wiring Diagram Pallet Truck Sheet 3 of 3 General Notes 8000 YRM 1512 4 ...
Page 203: ...Figure 2 Schematic Wiring Diagram Premium Walkie Sheet 1 of 7 8000 YRM 1512 General Notes 5 ...
Page 204: ...Figure 2 Schematic Wiring Diagram Premium Walkie Sheet 2 of 7 General Notes 8000 YRM 1512 6 ...
Page 205: ...Figure 2 Schematic Wiring Diagram Premium Walkie Sheet 3 of 7 8000 YRM 1512 General Notes 7 ...
Page 206: ...Figure 2 Schematic Wiring Diagram Premium Walkie Sheet 4 of 7 General Notes 8000 YRM 1512 8 ...
Page 207: ...Figure 2 Schematic Wiring Diagram Premium Walkie Sheet 5 of 7 8000 YRM 1512 General Notes 9 ...
Page 208: ...Figure 2 Schematic Wiring Diagram Premium Walkie Sheet 6 of 7 General Notes 8000 YRM 1512 10 ...
Page 209: ...Figure 2 Schematic Wiring Diagram Premium Walkie Sheet 7 of 7 8000 YRM 1512 General Notes 11 ...
Page 210: ...NOTES 12 ...
Page 211: ......
Page 212: ...8000 YRM 1512 3 18 12 14 1 14 12 13 7 13 4 12 ...
Page 213: ...Maintenance FRAME MPB045VG A245 PART NO 550093874 0100 YRM 1665 ...
Page 216: ......
Page 222: ...NOTES 6 ...
Page 223: ......
Page 224: ...0100 YRM 1665 7 16 12 13 ...
Page 225: ...Maintenance PERIODIC MAINTENANCE MPB045VG A245 PART NO 550093875 8000 YRM 1666 ...
Page 228: ......
Page 248: ...NOTES 20 ...
Page 249: ......
Page 250: ...8000 YRM 1666 3 19 2 19 10 15 6 15 3 15 12 13 ...
Page 251: ...Maintenance CONTROLLER DIAGNOSTICS MPB045VG A245 PART NO 550095689 9000 YRM 1671 ...
Page 337: ......
Page 342: ......
Page 349: ...Figure 6 Battery Charger Diagram GPT 2240 YRM 1890 Charging and Troubleshooting 7 ...
Page 360: ...NOTES 18 ...
Page 361: ......
Page 362: ...2240 YRM 1890 3 19 11 16 10 16 3 16 10 15 9 15 ...
Page 366: ......
Page 380: ...NOTES 14 ...
Page 381: ......
Page 382: ...2200 YRM 2030 6 17 11 16 10 16 ...