Troubleshooting Charger; Knowing When Battery Is Fully Charged; Where To Charge Batteries; Equipment Needed - Yale 524150797 Maintenance Manual

2240 YRM 0001
NOTE: Many users have battery chargers that can
follow a program to automatically charge a battery
according to recommendations of the battery
manufacturer. Use the recommendations of the battery
manufacturer for charging the battery.

Troubleshooting Charger

Battery chargers normally operate automatically
without constant attention. It is necessary to make a
periodic check that the charger is operating correctly.
Check for the following conditions:
1. Battery temperature is too high. The temperature
in a battery will not normally rise more than
14°C (25°F) during an 8-hour charging period.
Higher temperatures indicate the charging rate
needs adjustment.
2. Continuous operation of the charger. Check the
automatic controls on the charger. Check the
charging rate. A low charging rate can be the
problem.
3. Continuous operation of a charger at a high rate.
Normally, the charging rate begins at a high rate
and decreases as the battery becomes charged.
If the rate does not decrease, the controls need
repair or adjustment.

Knowing When Battery Is Fully Charged

WARNING
Always connect the positive cable to the positive
terminal and connect the negative cable to the
negative terminal. Any other connection will cause
injury and damage.
Always charge the battery at the end of the work
period (shift). Never let the specific gravity
decrease to a level less than the limits shown in
the manual.
Always de-energize
connect or disconnect the charger from the
battery.
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.
1. During charging, the voltage increases slowly.
When the battery is fully charged, the voltage
level is constant.
the charger before
2. Remove a vent cap and look in the opening. If
you see bubbles in the electrolyte, the battery is
either fully charged or in the final stage of
charging.
3. The specific gravity reading is constant and within
the limits of a charged battery. If the temperature
increases after the battery is charged, the specific
gravity will decrease a small amount.
4. Constant meter indications on the charger will
indicate the end of the charging cycle.

WHERE TO CHARGE BATTERIES

To increase the service life and reduce maintenance, a
special area is needed for charging the batteries. The
following information is necessary for the design of this
area:
Location of power supply
•
• Ventilation; hydrogen gas comes from the
batteries during charging
Drains for cleaning the batteries
•
Type and size of the batteries
•
Type of lift trucks
•
Distances the lift trucks must travel for service
•
Safety regulations and instructions
•

Equipment Needed

A lifting device to remove the battery from the lift
•
truck
Racks to hold the batteries during charging and
•
storage (these racks must be made of wood or
must not be metal; metal racks that are covered
with an insulating material can be used)
A battery charger that will charge your batteries
•
Tools for maintenance
•
An area with a drain for cleaning batteries and
•
battery compartments
you
Distilled water
•
Air and water supplies for cleaning
•
• Maintenance records (see Figure 11 and
Figure 12)
A workbench
•
Spare parts and repair equipment
•
Protective clothing and safety equipment for
•
handling batteries
Water source for washing eyes and preventing
•
acid burns
Battery Maintenance
15