Section 6. Component Procedures

00700-CL340-05, Issued: 2 May

Battery

The pallet truck may be equipped with a multiple (swingout) battery pack or a maintenance-free battery and charger.

Before working on the battery, batteries can weigh more than 500 pounds. Use extreme care during replacement. Use a suitable battery replacement device or hoist for lifting. See “Battery Safety” on page2-6.

Swingout Battery Pack

NOTE: For replacement parts information refer to Parts Catalog.

Removal (single battery)

1.After the truck is stopped and the handle is returned to the full up position, press the red OFF (O) key on the keypad.

2.Disconnect the battery connector found at the top of the tractor cover. Remove the battery cover.

3.Lift up on the top battery frame to get access to the lower two batteries.

4.As the frame is lifted, swing the battery toward the center of the forks.

5.The cables may now be disconnected from the battery terminals and the batteries may be serviced or replaced if necessary. See Figure6-2.

Installation (single battery)

1.Position the fully-charged and tested batteries in the battery pack.

2.Reconnect the battery cables to the battery terminals in accordance with the battery wiring hookup shown on the decal in the battery frame.

3.Reconnect the battery connector, reinstall the battery cover, press the green ON (I) key on the keypad, and test the operation of the pallet truck.

Removal (entire battery pack)

1.Press the red OFF (O) key on the keypad.

2.Disconnect the battery connector found at the top of tractor cover.

3.Position the battery replacement device above the battery and attach it to the battery manufacturer’s designated lift points.

4.Remove the battery with the lifting device.

5.Put the discharged battery on the charging stand.

Installation

1.With a fully charged and tested battery on the lifting device, position the lifting device in accordance with the manufacturer’s recommendations.

2.Position the battery in the compartment. Make sure the battery has no more than 1/2 in. (13 mm) of “free play” movement in the battery compartment in any direction.

3.Remove the lifting device from the area.

4.Reconnect the battery connector, turn the key switch ON, and test the operation of the truck.

Maintenance-Free Batteries

NOTE: For replacement parts information refer to Parts Catalog.

The truck may be equipped with a maintenance-free battery and charger pack. The specific gravity need not be measured on a maintenance-free battery. Please follow manufacturer’s recommendations for service of these batteries.

A maintenance-free battery still requires some care. The battery must be kept clean and dry and may be washed to remove any accumulated foreign matter. See “Exterior Cleaning” on page6-5.

Battery Maintenance Exterior Cleaning

1.Inspect the battery.

a.Make sure the cables are not frayed or loose.

b.Make sure there is no foreign material inside the connector.

c.Make sure the filler plugs are tight and the vent holes in the filler plugs are open. See Figure6-3.

2.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 clean the top of the battery with the soda solution while it is installed in the truck. Water will seep into the electrical compartments and cause serious damage.

3.Disconnect the battery connector, and remove the battery from the truck before you clean it.

4.Tighten the battery filler plugs.

5.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.

6.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.

7.Rinse the battery with clean water.

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

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

00700-CL340-05, Issued: 2 May 20056-5

Charging

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 page2-6.

5.Press the red OFF (O) key on the keypad, and disconnect the battery.

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 will increase during charging. See “Adding Water” on page6-7.

8.Using a hydrometer, measure and record the specific gravity of each cell. See “Specific Gravity” on page6-7.

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 will decrease 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 will severely damage 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 will increase battery capacity or increase 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 “Adding Water” on page6-7.

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.

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. Use only distilled water or water approved by the battery manufacturer. See “Battery Safety” on page2-6.

• 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.

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:

Procedure

1.Wear personal protective equipment. See “Battery Safety” on page2-6.

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 then: •Add just enough water to cover the battery plates

•Charge the battery, then take readings

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

Voltage Check

Take a voltage check on each cell after performing the specific gravity check. Attach a voltmeter to the positive and negative terminals of each cell. Voltage readings will change with the state-of-charge. See “Specific Gravity” on page6-7.

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.

Record the voltage reading for each cell on the battery maintenance chart. There must be a difference of less than 0.2V between cells.

00700-CL340-05, Issued: 2 May 20056-7