Raymond® Walkie Pallet Truck Maintenance Manual

Adding Water

Water must be added to battery cells periodically. Frequency and quantity depend on the water level above the plates and the amount of gassing during charge.

Guidelines:

•Wear personal protective equipment, see “Battery Safety” on page2-7. Use only distilled water or water approved by the battery manufacturer.

• Before charging, make sure battery plates are covered with electrolyte. Add water, if necessary, only to cover plates.

•Electrolyte level rises during charging. To avoid overflow, add water to fill port, if necessary, after charging, and after hydrometer and voltmeter readings are taken.

•Keep the outside of the battery case clean and dry.

Component Procedures Adding Water

Adding Water

Specific Gravity

Specific gravity readings for lead acid batteries with electrolyte temperatures at 80 F (27 C) vary with the state-of-charge as follows:

Most industrial deep-cell discharge batteries are considered discharged when 20% of the charge remains (specific gravity 1.140).

NOTE: Maintenance-free batteries do not require specific gravity checks.

Procedure:

1.Wear personal protective equipment. See “Battery Safety” on page2-7.

2.Insert the nozzle of the hydrometer into the battery cell and draw enough electrolyte into the tube to permit the float to ride free.

3.Leave the hydrometer nozzle in the battery and read the specific gravity of the cell.

4.If there is not enough electrolyte in the battery to get a hydrometer reading:

•Add just enough water to cover the battery plates

•Charge the battery, then take readings

5.Record the specific gravity reading on the battery chart.

Component Procedures

Voltage Check

Voltage Check

Take a voltage check on each cell after performing the specific gravity check on page 6-14. Connect the leads of a voltmeter to the positive and negative terminals of each cell. Voltage readings will vary with the state of charge:

Record the voltage reading for each cell on the battery maintenance char t. There should be a difference of no more than 0.2 volt between cells.

Maintenance-Free Batteries

The truck may be equipped with a maintenance-free battery and charger, in which case, the specific gravity need not be checked. See Figure6-7. Please follow manufacturer’s recommendations for service of these batteries.

A maintenance-free battery still requires some care. The battery should be kept clean and dry and may be washed to remove any accumulated foreign matter. See “Battery Exterior Cleaning” on page6-9.

Storage

Before you store a battery, make sure the electrolyte is at the prop er level in all the cells, the filler plugs are tight, and the battery is fully charged.

Store the battery in a clean, cool, dry location away from radiators and other sources of heat. Check the electrolyte level and the specific gravity every 30 days during storage. Whenever the specific gravity is less than 1.230, charge the battery.

Power Cables

Power Cables

Power cables should be checked for damage, including:

•Evidence of overheating

•Burned spots in the cable

•Nicks in the insulation

•Damaged or overheated terminal lugs

•Damaged mounting hardware or brackets

Repair or replace damaged cables or mounting hardware as necessary.

Power cables are marked on the terminal lug with the location where they belong. If the marking is missing or is not readable, remark the cable with the correct information.

The terminal lugs should be crimped tightly and securely on the wire. Replace the lug if overheating is evident and repair or replace faulty connectors as necessary.