Section 7.Component Procedures

To Charge a Battery

To charge a battery, direct current is passed through the battery cells in the direction opposite to that of discharge. Charging time is 5% to 20% longer than discharge time.

The most important element in battery service and prolonging battery life is correct charging. Make sure you follow the approved method for each application, following the battery and battery charger manufacturers’ instructions.

The vent holes in the filler plugs must be open to permit hydrogen gas to escape from the cells. When you charge the battery, make sure the polarity connections are correct. The positive lead of the charger must be connected to the positive terminal, and the negative lead must be connected to the negative terminal.

1.Familiarize yourself with the following:

•Charging rate, starting rate, and finish rate

•Time available for charge

•Overheating, excessive gassing, or overcharging

•Variations between cell voltage

2.Battery performance varies depending on the type of application. If you use more than one truck, one battery, and one charger, keep the same batteries and charger assigned to each truck. This makes it easier to diagnose any battery or charging problem.

3.Consult your battery and battery charger manufacturer’s manual for specific charging procedures.

4.Wear personal protective equipment, see “Battery Safety” on page2-5

5.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.

6.Inspect the battery.

7.Examine the electrolyte level in each cell. Electrolyte must cover the top of the battery plates. If electrolyte level is below the plates, add just enough water to cover the plates. Do not fill to level yet. Electrolyte level increases during charging. See “To Add Water to a Battery” on page7-41.

8.Using a hydrometer, measure and record the specific gravity of each cell. See “Battery Specific Gravity” on page7-41.

9.Measure and record the voltage of each cell.

10.To get the maximum use out of each battery, recharge only when effectively discharged. Routinely recharging batteries when only partially discharged decreases battery life. At maximum recommended discharge, the specific gravity must read 1.140 to 1.160 or less.

11.Make sure that the filler plugs are clean and the vent holes are open. Tighten all filler plugs.

NEVER plug the battery charger into the truck. This severely damages the truck’s electrical system. Plug the charger ONLY into the connector from the battery.

12.Charge the battery, following specific instructions in your battery and battery charger manufacturer’s manual.

13.Using a hydrometer, measure the specific gravity of each cell. No amount of charging increases battery capacity or increases specific gravity above its fully charged level (specific gravity 1.280 to 1.300).

14.If, after charging, the electrolyte level is below the fill port, add water to move it to the fill level. Do not overfill the cells or permit electrolyte to spill on the battery case. See “To Add Water to a Battery”.

In general, a lead-acid battery may be charged at any rate in amperes that does not cause excessive gassing or produce electrolyte temperatures above 110°F (43°C). Temperatures of 120°F (49°C) are permitted only for short periods of time.

To Charge a Raymond Battery Pack (Option)

NOTE: Make sure to follow battery manufacturer’s instructions included with the battery charger.

A battery/charger pack that uses a combination of four 6-volt batteries is optional on this lift truck. The battery pack includes a “self-contained” battery charger.

To charge the battery pack, do the following:

1.If equipped with the optional keypad, press the red OFF (O) key. Place the Main ON/OFF Switch in the OFF position (O).

2.Make sure the lift truck handle is in the upright position.

3.Plug the battery charger’s extension cord into a 120-volt outlet.

4.Charge the batteries.

5.The battery pack charging instruction decal defines the various status indicator lights on the battery pack.

After the battery pack is charged:

1.Unplug the battery charger’s extension cord from the outlet.

2.Return the battery charger’s extension cord to the storage space provided.

To Add Water to a Battery

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. Use only distilled water or water approved by the battery manufacturer. See “Battery Safety” on page2-5

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

•Electrolyte level increases during charging. To prevent 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.

Battery Specific Gravity

Specific gravity readings for lead acid batteries with electrolyte temperatures at 80°F (27°C) change 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 measurements.