Maintenance Section
112
Battery
WARNING
When using pressure air for cleaning purposes,
wear a protective face shield and protective
clothing. Maximum air pressure must be below
207 kPa (30 psi).
Do not smoke near batteries that are being
stored or when checking the electrolyte level.
Electrolyte is an acid solution and can cause
personal injury. Avoid contact with skin and
eyes.
Maximum life and performance of lift truck batteries
is dependent on the operator, battery charging,
maintenance and service.
Most dirt and dust picked up by the battery can
usually be blown off with low pressure compressed
air.
However, if cells are overfilled and electrolyte
collects on the covers, the top of the battery will
stay wet.
If necessary, clean the top of the battery with a
solution of baking soda and hot water.
NOTICE
Vent caps must be tight to prevent soda solution
from entering battery cells.
To make the solution, add 0.5 kg (1 lb) of baking
soda to 4 liters (1 gallon) of water. Use a brush
having flexible bristles. Apply the soda solution to
the top of the battery until the cleaning action of the
soda stops.
After cleaning action has stopped, rinse batteries
thoroughly with water. Dry the batteries with low air
pressure.
The lift truck operator must not start his shift with a
battery that has been taken off a charger too soon.
Batteries are designed to be charged and allowed
to cool and stabilize. A battery should never be
disconnected from a charger until the charge cycle
has been completed.
Low battery operation must be prevented.
Operation with a low battery may cause damage to
the battery.
Low battery operation will cause higher than normal
current in the electrical system. This can damage
contactor tips or shorten motor brush life.
Batteries that have been fully charged should have
a tag attached for identification.
A battery should be recharged in 8 to 12 hours after
being discharged, depending on the charger type,
then allowed to cool and stabilize 4 to 8 hours.
Repeated undercharging must be prevented
because it can damage the battery.
A battery requires an equalizing charge at least
once every 20 normal charge/discharge cycles.
This helps correct and prevent unequal cell specific
gravity (SG) readings. An “equalizing charge” is a
cycle charge with modification, given usually at an
interval to bring all cells up to a state of equal
charge. An equalizing charge usually adds three to
four more hours to the cycle charge, at a low finish
rate. It is usually given when the specific gravity
(SG) of electrolyte has a variation of more than 20
points (.020) from cell to cell, after a regular cycle
charge.
A “cycle charge” will completely recharge the
battery. The typical cycle charge for a fully
discharged battery usually is an eight-hour charge.
The battery must be recharged before it has been
discharged over 80% of the rated capacity of the
battery. The work shift of the lift truck can be
planned so the battery will not be discharged more
than 80%.
A battery should never be left in a discharged state
because of sulfate formation. This reduces battery
life drastically. To extend life always recharge the
battery without delay after it has been discharged.
Repeated over discharging of the battery will
damage the cells, which will shorten battery life and
increase operating cost. Battery life(number of
cycles) decreases as the depth of discharge
increases. The estimated life of the battery
discharged to 80% will be approximately twice as
long as if it were discharged 100%.
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