2240SRM0001 (02 2008) Uk en PDF
2240SRM0001 (02 2008) Uk en PDF
2240SRM0001 (02 2008) Uk en PDF
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Industrial Battery Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Lead-Acid Batteries ........................................................................................................................................... 1
Specific Gravity .................................................................................................................................................. 2
Chemical Reaction in a Cell .............................................................................................................................. 2
Electrical Terms ................................................................................................................................................. 3
Battery Selection................................................................................................................................................ 4
Battery Voltage .................................................................................................................................................. 5
Battery as a Counterweight .............................................................................................................................. 5
Battery Ratings.................................................................................................................................................. 6
Kilowatt-Hours .............................................................................................................................................. 6
Battery Maintenance ......................................................................................................................................... 6
Safety Procedures .......................................................................................................................................... 6
Maintenance Records .................................................................................................................................... 7
New Battery ................................................................................................................................................... 7
Cleaning Battery ........................................................................................................................................... 7
Adding Water to Battery ............................................................................................................................... 9
Hydrometer .................................................................................................................................................... 10
Battery Temperature ..................................................................................................................................... 10
Charging Battery ........................................................................................................................................... 11
Types of Battery Charges.......................................................................................................................... 12
Methods of Charging ................................................................................................................................. 13
Troubleshooting Charger .......................................................................................................................... 14
Knowing When Battery Is Fully Charged ............................................................................................... 14
Where to Charge Batteries............................................................................................................................ 14
Equipment Needed .................................................................................................................................... 14
Battery Connectors........................................................................................................................................ 15
Battery Care .................................................................................................................................................. 15
HYSTER
APPROVED
PARTS
2240 SRM 1 Lead-Acid Batteries
General
This section describes how to select and do the main- batteries have a nameplate attached to the face of the
tenance for large batteries used in electric lift trucks. battery cover. This nameplate communicates specific
This information is for service personnel that must information about the battery including the name of
do the maintenance on large lead-acid batteries. Bat- the battery manufacturer, battery type, serial num-
tery repair requires special training and equipment. ber, nominal voltage, capacity in amperes at the five-
Do not try to repair a battery unless you have the cor- hour rate, and service mass (with ballast if used to
rect tools, equipment, and experience. Most battery compensate for lack of battery mass).
repairs are done by a special repair service. Some
Lead-Acid Batteries
A lead-acid battery converts chemical energy into
electrical energy. See Figure 1. Chemical changes
within the battery give the electrical energy. When
the chemical reaction has occurred so the battery
will not give its rated voltage and current, the bat-
tery is discharged. A reverse chemical action must
occur so the battery can be used again. The batteries
described in this section can be charged again by an
electric voltage and current from an outside source
so there is a reverse chemical action. The lead-acid
chemicals store the electric energy until the electric
energy is needed to operate an electric device.
1
Chemical Reaction in a Cell 2240 SRM 1
Specific Gravity
The strength of the electrolyte is measured in points of specific gravity. For example, a solution of sulfuric
acid has a specific gravity of 1.835. Water has a specific gravity of 1.000. Electrolyte is 27 percent acid and 73
percent water and has a specific gravity of 1.275.
2
2240 SRM 1 Electrical Terms
Electrical Terms
Voltage: Is an electromotive force (EMF) (also called maintenance-free battery, the amount of free-stand-
"potential difference") caused by the difference in ing electrolyte above the plates is much higher, en-
electric charge between two points. See Figure 7. suring enough electrolytes to keep the plates covered
during extended periods of use. Therefore, there is
Ampere: Is a measurement of electric current. no need to add water to a maintenance-free battery
during the course of its life.
Watt: Is a measure of electric power. The number
of watts is equal to the number of volts multiplied Flooded Cell: This is a lead acid battery that has
by the number of amperes. A kilowatt-hour is 1000 free flowing electrolyte fluid in each cell of the bat-
watts of electric power used in 1 hour. tery. The electrolyte is a mixture of sulfuric acid and
water.
Ohms: Is the measurement of electrical resistance.
Direct Current (DC): When the voltage between
Polarity: In a battery, the electric current is shown
the two terminals is always the same polarity, the
to flow from the positive terminal to the negative ter-
current flow and voltage are called Direct Current.
minal.
Alternating Current (AC): When the polarity of
Maintenance-Free Battery: The electrolyte level
voltage between two terminals is changing between
in the battery does not need to be checked during
positive and negative at a quick and constant rate,
the life of the battery. Maintenance-free batteries
the voltage is called Alternating Current.
use a calcium alloy of lead instead of an antimony
alloy, which reduces the amount of electrolysis. In a
3
Battery Selection 2240 SRM 1
Battery Selection
NOTE: The capacity of the battery can be found on
the lift truck’s Nameplate. See the Frame section or
Operating Manual for your lift truck for the loca-
tion of the Nameplate.
4
2240 SRM 1 Battery as a Counterweight
Battery Voltage
NOTE: The voltage of the battery can be found on the To reach the necessary battery voltage, the cells are
lift truck’s Nameplate. See the Frame section or Op- connected in series. For example:
erating Manual for your lift truck for the location 24 volts = 12-cell battery
of the Nameplate. 36 volts = 18-cell battery
48 volts = 24-cell battery
The battery voltage you need is found as follows: 72 volts = 36-cell battery
• Will your lift truck operate on more than one volt- 80 volts = 40-cell battery
age?
• If you have more than one lift truck in operation,
do the battery voltages need to be the same?
Battery as a Counterweight
On electric lift trucks that use the battery as part See the Frame or Periodic Maintenance service
of the counterweight, the battery is part of the ca- manual or Operating Manual for your lift truck
pacity of the lift truck to lift loads. The minimum model for the correct measurements for installing
weight of the battery is shown on the nameplate. If battery spacers.
the battery is not the minimum weight, the capacity
of the lift truck is reduced. If the battery used in the
lift truck is less than the size of the battery compart-
ment, blocks and spacers must be installed to hold
the battery in position.
5
Battery Maintenance 2240 SRM 1
Battery Ratings
The ratings of batteries are measured in ampere- KILOWATT-HOURS
hours and kilowatt-hours at a constant rate of dis-
charge. A rating of 6 hours is the standard. Ampere- A kilowatt is 1000 watts. A watt is a measure of
hours is the measurement of battery capacity. To electric power. The capacity in kilowatt-hours is the
calculate ampere-hours, multiply amperes by hours. total power generated by the battery. Watt-hours
See Table 1. For example, 5 amperes times 5 hours are measured by multiplying the voltage by ampere-
is 25 ampere-hours. You cannot change the potential hours. To measure the kilowatt-hours, divide the
difference of a cell. You can increase the ampere-hour watt-hours by 1000.
rating by increasing the number of plates in a cell,
volts × amperes × hours
or by installation of larger plates. The constant rate = kilowatt-hours or kWh
of discharging can be compared to a measurement of 1000
the battery capacity and ampere-hours. For exam-
ple, a battery with a rating of 600 ampere-hours dur- To calculate the kilowatt-hours for a battery that has
ing a work period of 6 hours will generate 100 am- a rating of 600 ampere-hours and a 48-volt system,
peres per hour for 6 hours. The same battery cannot use this formula:
generate 300 amperes for 2 hours. The heat gener-
ated within the battery will damage the battery. 48 volts × 600 amperes × hours
= 28.8 kWh
Table 1. Battery Capacity Terms 1000
Battery Maintenance
Battery maintenance must include the following match or a lighter. Do not smoke and do not cre-
items: ate sparks.
• A good battery charger
• A clean battery 3. Lift batteries correctly with a crane or equipment
• Keep the electrolyte at the correct level (see Fig- designed for the job. Always use a spreader bar
ure 13) designed and adjusted for the battery. Move bat-
• Keep a record of the battery teries with a lift truck or a conveyor or rollers de-
• An Equalization Charge once a month signed for that purpose. If the battery does not
have a cover, a rubber mat or insulating material
SAFETY PROCEDURES must be put over the top of the battery to prevent
a short circuit with other equipment. Make sure
1. Wear a rubber apron, gloves, boots, and goggles the lifting equipment has enough capacity for the
or a face shield when doing maintenance on bat- job. Do not use chain or wire rope slings.
teries.
4. Never put metal materials or tools on a battery.
2. Batteries generate hydrogen gas when they are
being charged. Keep open fire away from bat- 5. Disconnect battery from lift truck before doing
teries. Do not check the electrolyte level with a maintenance or repairs.
6
2240 SRM 1 Battery Maintenance
6. When maintenance on the battery or the battery vent caps must be in position when the battery
charger is required, disconnect both the AC and is in service. If the vent caps are not installed,
DC power. If the battery connectors must be re- the electrolyte will leak, causing corrosion on
placed, make sure the positive and negative ter- the battery case and in the battery compart-
minals and cables are kept separate and insu- ment.
lated from each other. Even a momentary short
circuit can cause an explosion and damage the Inspect a new battery for damage. Make sure the
battery. electrolyte in each of the cells is at the correct level.
Charge the battery for 6 hours or until the specific
7. Keep water readily available to flush spilled elec- gravity is correct. Make sure the battery is correctly
trolyte. Electrolyte in the eyes must be flushed installed in the lift truck. Use a spreader bar with
with water immediately, and then quickly get slings designed for the battery to lift and move the
medical attention. Special showers and eye battery. See Figure 10.
wash systems are required in areas where bat-
tery maintenance is done. Always complete the Battery Inspection Report and
the Daily Battery Report. See Figure 11 and Fig-
8. If electrolyte is spilled on a work surface or the ure 12.
floor, flush area with water, use a solution of soda
(sodium bicarbonate) to make the acid neutral. CLEANING BATTERY
9. Only trained persons are permitted to do main-
WARNING
tenance on batteries and battery chargers. Make
sure the regulations by government safety agen- Compressed air can move particles so that they
cies, government insurers, private insurers, and cause injury to the user or to other personnel.
private organizations are followed when doing Make sure that the path of the compressed air
maintenance on batteries. is away from all personnel. Wear protective
goggles or a face shield to prevent injury to the
MAINTENANCE RECORDS eyes.
NOTE: Follow the same sequence when you record Keep the battery compartment clean and dry. Use a
the cell number. Always begin the record with a pos- clean cloth to wash the battery with water. Dry with
itive cell. Follow a sequence so the last cell is always compressed air.
the cell for the negative cable.
CAUTION
Record the beginning ampere reading of the charger
each time the battery is charged. Any difference in Do not clean the battery with steam or hot wa-
the daily ampere reading can indicate a problem with ter. Do not use a high-pressure hose.
the battery or the charger. Remove any electrolyte from the battery compart-
ment to prevent corrosion. If there is electrolyte on
NEW BATTERY the top of the battery, apply a solution of bicarbonate
of soda. Mix a solution containing 0.5 kg of soda for
CAUTION every 4 liters of water. Apply the solution, then flush
Always use a spreader bar and slings that lift the solution from the battery with clean water. Wash
vertically on the lifting eyes of the battery. DO the battery and battery compartment as needed, but
NOT use a chain or sling without a spreader within a 6-month period as the maximum time.
bar or you will damage the battery case.
NOTE: If the top of the battery is wet from electrolyte,
Use the correct blocks or spacers to hold the check that the electrolyte level is not too high or the
battery in position in the lift truck. Make sure battery charger is not operating correctly.
the battery compartment is clean and dry. All
7
Battery Maintenance 2240 SRM 1
8
2240 SRM 1 Battery Maintenance
ADDING WATER TO BATTERY vent plugs. The electrolyte can flow out of the cell
through the fill hole. The correct electrolyte level is
NOTE: Some batteries have sealed cells. These bat- shown in Figure 13.
teries do not need water added to the electrolyte.
9
Battery Maintenance 2240 SRM 1
10
2240 SRM 1 Battery Maintenance
WARNING
The acid in the electrolyte can cause injury.
If electrolyte is spilled, use water to flush the
area. Make the acid neutral with a solution of
sodium bicarbonate.
CAUTION
Use only battery chargers approved by the bat-
tery manufacturer or dealer.
CAUTION
NEVER connect the battery charger plug to
the plug of the lift truck. You can damage the
traction control circuit. Make sure the charger
voltage is the correct voltage for the battery.
11
Battery Maintenance 2240 SRM 1
12
2240 SRM 1 Battery Maintenance
13
Battery Maintenance 2240 SRM 1
14
2240 SRM 1 Battery Maintenance
A special heavy-duty connector is used to connect the 1. SB CONNECTOR FOR BATTERY CABLES
battery to the electrical system of the lift truck. See 2. SB CONNECTOR FOR POWER CABLES TO
LIFT TRUCK
Figure 22 and Figure 23. When a connector has a 3. BRACKET
handle and is within the operator’s reach, the connec- 4. CONNECT AND DISCONNECT HANDLES
tor is also a safety device that can be used to quickly
disconnect the battery in an emergency. Most con- BATTERY CARE
nectors have a handle to connect the two halves of the
connector. The connector can be quickly disconnected 1. Keep batteries clean. Remove any spilled elec-
by pulling the handle upward. This action separates trolyte.
the two halves of the connector. The connector and
its attached handle must be kept in good repair so 2. DO NOT overcharge the battery. This action will
that it will function correctly. The battery connec- damage the battery.
tor must be disconnected when maintenance is done 3. DO NOT discharge the battery to less than the
on the lift truck that does not require electric power. recommendation. A deep discharge will shorten
The SBE, SBX, and FEM or DIN 12- volt battery con- the battery life.
nectors are shown in Figure 23.
4. Charge batteries in an area with good ventilation
to remove explosive gases and acid fumes.
15
Battery Maintenance 2240 SRM 1
NOTE: INDICATOR INSERT (2). GREEN - FOR BATTERY WITH CELL CAPS. GRAY - FOR BATTERY WITH
SEALED CELLS.
NOTE: CONNECTOR BODY COLOR [ANDERSON SBE CONNECTOR ONLY (1)]. GRAY - 36-VOLT BATTERY.
BLUE - 48-VOLT BATTERY. GREEN - 72-VOLT BATTERY. BLACK - 80-VOLT BATTERY.
A. ANDERSON SBE OR SBX CONNECTOR B. FEM OR DIN CONNECTOR
1. HALF OF CONNECTOR SET 9. +12 VOLT WIRE TO TRUCK (TRUCK HALF) OR
2. RED HOUSING FOR +12 VOLT "BATTERY TAP" TO BATTERY (BATTERY HALF)
3. LOCK SPRING (TIP OF CONTACT MUST LOCK 10. INDICATOR INSERT FOR BATTERY VOLTAGE
OVER TOP OF LOCK SPRING) AND BATTERY TYPE [ROTATE FOR CORRECT
4. BLACK CONNECTOR HOUSING (ASSEMBLED VOLTAGE IN WINDOW (12); COLOR SHOWS
ON RED HOUSING WITH SLOTS FOR LOCK BATTERY TYPE]
PINS ALIGNED AS SHOWN - NO WIRE OR 11. LOCK FOR ALL CABLE TERMINALS AND
CONTACT IN HOUSING) INDICATOR
5. SLOT FOR LOCK PIN 12. WINDOW SHOWING BATTERY VOLTAGE
6. CONTACT FOR CONNECTOR OF +12 VOLT 13. IN-LINE FUSE ASSEMBLY AND CONTACT
BATTERY TAP FOR +12 VOLT CONNECTOR (TRUCK HALF
7. KEY [RED (2) AND BLACK (4) CONNECTORS OF BATTERY CONNECTOR ONLY) (SBE/SBX
ALIGN ON KEY] CONTACT SHOWN)
8. LOCK PINS FOR +12 VOLT CONNECTOR (MUST
INSTALL FROM FRONT OF CONNECTOR
THROUGH RED AND BLACK CONNECTORS)
16
TECHNICAL PUBLICATIONS