Model 6210 Maintenance Manual

Section 7.Component Procedures

Electrical Components Battery

4.Remove the battery pack cover.

5.Swing out the top battery trays.

6.Disconnect all cables and wires from the charger assembly to the batteries. Note the orientation and location for reconnection.

7.Remove the screws and nuts securing the charger unit to the battery tower.

8.Slide the charger unit out of the battery tower.

9.Disconnect all cables and wires from the charger assembly. Note the orientation and location for reconnection.

10.Connect cables and wires to the new charger. Make sure the orientation and location is the same as previously noted.

11.Place the new charger unit in the battery tower in the same orientation as the one that was removed.

12.Secure the charger to the battery tower frame with bolts and nuts. Use a 10mm wrench to hold the nuts while torquing the bolts to 89 in. lb. (10 Nm).

13.Connect the cables from the charger to the batteries. Follow the battery wiring hookup shown in Figure7-52. Make sure to loop cables and secure with cable ties.

Figure 7-53.Battery Cables Looped and Secured your PIN-key code and then press the green ON ( | ) key. a.Plug the AC power cord into an outlet. b.Wait approximately 1 minute. The yellow lightening bolt on the charger will light up to confirm correct charger operation.

17.Configure the truck parameter 21 for the battery type installed. See “Programming Service Parameters” on page3-12.

18.Test the charger operation.

14.Torque terminal nuts to 101 in. lb. (11.4Nm) for wet cell batteries. Torque nuts to 89 in. lb. (10 Nm) for AGM batteries.

15.Install terminal caps.

16.Reconnect the battery connector. Place the Main ON/OFF Switch in the ON position. If equipped with the optional keypad, enter c.Unplug the AC power cord.

19.Install the battery cover. Figure 7-55.

20.Wind the charger cord around the storage handle on the battery cover.

21.Install the lower and grille covers.

Publication: 1146947, Revised: 12 Jan 2017 7-37

Removal (Industrial Battery)

1.Park truck on a level surface and make sure parking brake is applied.

2.If equipped with the optional keypad, press the red OFF ( O ) key. Place the Main ON/OFF Switch in the OFF position. Disconnect the battery connector from the truck.

3.Position battery replacement device in accordance with the supplier’s recommendations.

4.If applicable, remove the bolts from the battery box frame on the truck. Remove the battery from the truck onto a suitable battery table or with a battery lifting device.

Installation (Industrial Battery)

1.With a fully charged and tested battery on the battery handling device, position the handling device at the truck in accordance with the supplier’s recommendations.

2.Move the battery into the compartment. Make sure the batter y has no more than 0.50 inch (13 mm) of “free play” movement in the battery compartment. If applicable, securely refasten bolts to the battery box frame on the truck.

3.Move the battery handling device from the area.

4.Reconnect the battery connector to the truck.

5.Place the Main ON/OFF Switch in the ON position. If equipped with the optional keypad, enter your PIN-key code and then press the green ON ( | ) key.

6.Test the truck for correct operation before returning to service.

Inspection and Care

Battery electrolyte is a solution of sulfuric acid and water. Battery acid causes burns. Should any electrolyte come in contact with clothing or skin, flush the area immediately with cold water. Should the solution get on your face or in your eyes, flush the area with cold water and receive medical attention immediately.

Before working on the battery, review Battery Safety beginning on page2-5. Industrial batteries and assembled battery packs can weigh more than 500 pounds (227kg). Use extreme care during replacement. Use a suitable replacement device or hoist for lifting.

NOTE: Read, understand, and follow procedures, recommendations, and specifications availa ble by the battery and battery charger supplier.

Batteries in industrial trucks pick up various kinds of dirt and dust depending on their surroundings and the types of material handled. If cells are overfilled and electrolyte collects on the covers, the following occurs:

1.The top of the battery becomes wet and stays wet, since the acid in the electrolyte does not evaporate.

2.This moist surface, in combination with certain kinds of dirt, becomes electrically conductive and permits stray currents to flow externally over the top of the battery. This degrades battery performance and truck operation.

3.The acid also causes corrosion of cell posts, nuts, connectors, and the steel battery case.

4.When inspecting batteries, check the following:

•Wet covers can indicate overfilling, leaky seals at posts, or excessive gassing during charge. If covers are wet, determine the cause and correct the problem.

•Make sure batteries cannot move more than 0.5 inch (13 mm) in any horizontal direction. Shim or block the batteries to restrain them.

Battery Exterior Cleaning

1.Read, understand, and follow procedures, recommendations, and specifications in the battery and battery charger manufacturer’s manuals.

6.Keep the top of the battery clean and dry. Corrosion, dust, and moisture provide a conducting path to short-circuit cells or create grounds.

Do not use soda solution to clean the top of the battery while it is installed in the truck. Water can seep into the electrical compartments and cause serious damage.

7.Tighten the battery filler plugs.

2.Wear personal protective equipment. See “Battery Safety” on page2-5.

3.If equipped with the optional keypad, press the red OFF ( O ) key. Place the Main ON/OFF Switch in the OFF position. Disconnect the battery connector from the truck. Remove the battery from the lift truck.

4.Inspect the battery cables to make sure they are not frayed or loose. Inspect the battery connector to make sure there is no foreign material inside the connector.

5.Make sure the filler plugs are tight and the vent holes in the filler plugs are open. See Figure7-56.

8.Wash dirty batteries (or any that have had electrolyte spilled on them) with a solution of 1 lb. (0.45 kg) of baking soda added to 1/2 gal (1.9 liters) of hot water.

9.Use a brush with flexible bristles to clean the entire top of the battery with the soda solution. Wait until all foaming stops, indicating that the battery exterior is neutralized.

10.Rinse the battery with clean water.

11.Dry the battery completely before re-installing it.

12.Reinstall the battery in the truck, using a suitable battery moving device. Reconnect the battery connector.

13.Apply a thin coat of petroleum jelly to the battery posts and cable terminals.