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 1. 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. Do not permit the specific gravity to go below
the limits shown in the manual.
Battery Maintenance
Battery maintenance must include the following items:
•
A good battery charger
•
A clean battery
•
Keep the electrolyte at the correct level (see
Figure 13)
•
Keep a record of the battery
•
An Equalization Charge once a month
SAFETY PROCEDURES
1. Wear a rubber apron, gloves, boots, and goggles
or a face shield when doing maintenance on
batteries.
2. Batteries generate hydrogen gas when they are
being charged. Keep open fire away from
batteries. Do not check the electrolyte level with a
match or a lighter. Do not smoke and do not
create sparks.
3. Lift batteries correctly with a crane or equipment
designed for the job. Always use a spreader bar
designed and adjusted for the battery. 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. Do not use chain or wire rope slings.
4. Never put metal materials or tools on a battery.
5. Disconnect battery from lift truck before doing
maintenance or repairs.
6. 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.
7. Keep water readily available to flush spilled
electrolyte. Electrolyte in the eyes must be
flushed with water immediately, and then quickly
get medical attention. Special showers and eye
wash systems are required in areas where battery
maintenance is done.
8. If electrolyte is spilled on a work surface or the
floor, flush area with water, use a solution of soda
(sodium bicarbonate) to make the acid neutral.
2240 YRM 0001 Battery Maintenance
7
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