BATTERY & CHARGER

SECTION BC
CONTENTS
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . BC-2 ONBOARD BATTERY
BATTERY / CHARGER PRECAUTIONS . . . BC-3 CHARGER OPTION . . . . . . . . . . . . . . . . . BC-21
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . BC-5 Battery Charger Specifications . . . . . . . . . . BC-21
Theory and Construction of BATTERY CHARGER INFORMATION . . . . . BC-22
Lead-Acid Storage Batteries . . . . . . . . . . BC-5 Optional On Board Charging . . . . . . . . . . . . BC-22
Battery Construction . . . . . . . . . . . . . . . . . . BC-5 Using The On-Board Charger . . . . . . . . . . . BC-22
Specific Gravity . . . . . . . . . . . . . . . . . . . . . . BC-7 During Changing Operation
The Chemical Reaction . . . . . . . . . . . . . . . . BC-7 (Green Led Indicator Light) . . . . . . . . . . . BC-22
Trouble Diagnoses and Corrections . . . . . . . BC-9 OPTIONAL BATTERY PACK CARE
BATTERY MAINTENANCE . . . . . . . . . . . . . BC-11 AND MAINTENANCE . . . . . . . . . . . . . . . . BC-23
Cleaning the Battery . . . . . . . . . . . . . . . . . . BC-11 Battery Options . . . . . . . . . . . . . . . . . . . . . . BC-23
Supplying Distilled Water . . . . . . . . . . . . . . . BC-12 Optional Battery Pack . . . . . . . . . . . . . . . . . BC-23
The Hydrometer . . . . . . . . . . . . . . . . . . . . . BC-13 OPTIONAL BATTERY PACK
PARTS DESCRIPTION . . . . . . . . . . . . . . . BC-25
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . BC-14
Wet Cell Pack . . . . . . . . . . . . . . . . . . . . . . . BC-25
Battery Temperature . . . . . . . . . . . . . . . . . . BC-15
Maintenance Free . . . . . . . . . . . . . . . . . . . . BC-26
BATTERY CHARGER . . . . . . . . . . . . . . . . . . BC16
EE Battery Pack Cover . . . . . . . . . . . . . . . . BC-27
Charging The Battery . . . . . . . . . . . . . . . . . BC-16
OPTIONAL BATTERY PACK REMOVAL . . . BC-28
Types Of Battery Charges . . . . . . . . . . . . . . BC-16
Battery Cover Removal . . . . . . . . . . . . . . . . BC-28
BATTERY CHARGE INFORMATION . . . . . . BC-17
Battery Pack Removal . . . . . . . . . . . . . . . . . BC-28
Battery Chargers . . . . . . . . . . . . . . . . . . . . . BC-17
Industrial Battery Removal . . . . . . . . . . . . . . BC-28
Battery Charge Classifications . . . . . . . . . . . BC-18
Charging Preparations . . . . . . . . . . . . . . . . . BC-19
Storing the Battery . . . . . . . . . . . . . . . . . . . BC-20

! CAUTION
• Before changing any components (i.e. lamps,
fuses, meter panels) or disconnecting any
wiring. Always turn OFF the Ignition Switch
and disconnect the Battery. This will reduce
the possibility of damage to the Controller
System.
NOTE:
• This section describes the general precautions
and maintenance information for the handling and
charging of the Battery.
• For the actual handling and charging of the
Battery, please confirm with the instruction manual
of the battery and charger used.
PRECAUTIONS

Precautions
!! WARNING
• Do not smoke or place any fire near the battery being
serviced or handled.
• During battery maintenance, always wear safety goggles,
rubber gloves and rubber boots.
• Be careful not to spill electrolyte on your body or clothes
as this may cause injury or chemical burns.
• If electrolyte flows out or leaks from the battery case,
immediately dilute with a neutralizing detergent (such as
sodium bicarbonate, calcium hydroxide, etc.) and then
rinse with a large amount of running water.
• Never place any metal objects (such as tools, etc.) on or
across battery terminals. This may ignite and explode
hydrogen gas emitted from the battery or cause damage
to the battery and personal injury.
• Static electricity may explode the battery. Do not attempt
to wipe or clean the upper surface or terminals of the
battery with a dry cloth or do not place a vinyl cover over
the battery. Always wipe clean the battery case with a wet
cloth.

! CAUTION
• Electrolyte leakage may corrode the battery itself. Always
tighten battery vent caps firmly.
• Do not allow any one who is unfamiliar with battery
handling instructions to inspect the battery.

BC-2
BATTERY / CHARGER PRECAUTIONS

! CAUTION
The following general information describes the best methods for
using and maintaining the battery and it in no way covers every
manufacturer of battery/chargers. Contact the manufacturer of the
battery or charger to ensure their recommended procedures and
operation methods of the equipment are followed.
In cases of a battery not taking a charge, make sure the charger is
being attached to the battery connector and not to the connector on
the unit. A battery which does not take a proper charge should be
referred to the battery manufacturer’s representative for service.
Refer to the appropriate manuals attached to the battery for
information about how to handle and maintain the battery. Proper
care and servicing of the battery is vital to ensure satisfactory
operation and life of the electric truck. Battery acid is extremely
corrosive and should be washed off the unit if any spills occur.

! CAUTION
• Do not allow the alkaline solution to fall in the Battery cell.
This will result in a dead or weak Battery.
• Check with Local and State Regulations on the storing,
charging and cleaning of corrosive materials. There may
be conditions locally which will not allow for the simple
washing off of acid spills.

!! WARNING
• Only trained and authorized personnel should conduct
maintenance or servicing of this unit and its battery.
• Always turn the Ignition Switch OFF and disconnect the
Battery before doing any servicing of the Battery.
• Always wear personal protective equipment (PPE)(i.e.
safety goggles, rubber gloves and boots) when servicing
the Battery. Battery acid will cause severe burns or injury.
• The Battery generates highly explosive hydrogen gas. A
short circuit resulting in sparks or even a lit cigarette in
the vicinity of the Battery can cause a serious explosion.
Do not permit smoking, open flames or sparks near the
Battery or Battery maintenance area. Be particularly
careful during Battery charging and for the first 30
minutes following Battery charging.
• Battery fluid contains highly corrosive sulfuric acid. If acid
contacts skin or clothing, flush the area immediately with
large amounts of clean, fresh water. If acid enters the
eyes, immediately flush eyes with large amounts of clean
fresh water and contact a physician. If acid is accidentally
swallowed, contact a physician immediately.
• If a large quantity of Battery fluid is spilled, neutralize it
with an equivalent quantity of basic neutralizing agent
(baking soda, calcium hydroxide, or sodium carbonate).
Wash away the resulting solution with large quantities of
clean fresh water. Always follow any and all Local, State
and Federal Regulations for Hazmat spills.

BC-3
BATTERY / CHARGER PRECAUTIONS

!! WARNING
• When changing industrial batteries, replacement
batteries shall be of the service weight that falls within
the minimum/maximum range specified on the truck data
plate by the truck manufacturer.
• Do not place tools or other metallic objects on the top
surface of the battery where they may come in contact
with the battery terminals and cause an electrical short.
This electrical short may cause sparking. The sparking
may ignite the hydrogen gas escaping from the battery
resulting in a serious explosion. It may cause some
nearby object to burn.
• Battery fluid exhaustion (gases) creates the danger
of explosion. Replenish the battery fluid frequently to
maintain the specified fluid level. During battery charging,
the proportion of water in the battery fluid decreases.
Before battery charging, always check that the battery
fluid level is above plates. If the fluid level is low, replenish
it with distilled water to cover the plates. Do not overfill to
standard level.
• After charging is complete fill cells to the standard fill
level.
• During battery charging, there is a high risk of hydrogen
gas explosion. To reduce this risk, always perform battery
charging in a well-ventilated room or area. Continue
ventilation for at least 30 minutes after the completion of
charging.
• Do not attempt to recharge a frozen battery; this may
cause it to rupture or explode.
• Cleaning the battery upper surface and connections with
certain types of dry cloth or laying a dust cover or vinyl
sheet across these areas may create a static electricity
charge that can lead to dangerous sparking. An explosion
can result. Do not use dust covers or vinyl sheets to
protect the battery. If you are cleaning battery surfaces,
use a slightly damp cloth.

! CAUTION
• Do not allow a battery to overly or completely discharge.
Recharge the battery immediately after the red Alarm
LED begins to blink and the wrench symbol and alarm
code display on the MDI. Do not operate the forklift until it
simply stops running and then recharge the battery. This
technique will result in greatly reduced battery service
life. After completing forklift operations, park the forklift
and immediately begin battery charging. Do not store
a discharged battery for an extended period of time.
Recharge a battery before storing.
• The battery and its surroundings should be kept clean and
dry at all times. Keep the battery plugs tightly closed to
prevent the leakage of battery fluid. Battery fluid leakage
will result in battery corrosion.

BC-4
 BATTERY

• The Battery for a lift truck represents a sizable investment. It is

important to select and purchase the correct Battery for the job.
Taking care of the Battery in the best possible way makes the
most of the investment.
• This section describes how to take care of the Battery. It also
explains how that Battery works. When the mechanics of the
Battery are understand, you are better able to take care of it.
• Some material presented in the text is not new. Information
EYE has been gathered from manufacturers of Batteries and
related equipment. It is presented here to help you, the service
PROTECTION technician, understand and take care of Batteries.
REQUIRED !! WARNING
• When working with any Battery, always wear protective
equipment, such as Rubber Gloves, Rubber Apron and
Protective Face Shield. No smoking at any time when
working near a Battery area.

Theory and Construction of Lead-Acid

Storage Batteries
Storage Batteries do not actually store electrical energy. Instead
they accept the electrical energy delivered to them during charging
periods and convert it into chemical energy. A Battery in use is said
to be discharging. During discharging, the chemical energy in the
Battery is converted into usable electrical energy.

Battery Construction
The internal construction of a Lead-Acid Industrial Motive Power
Battery is similar to that of the common automobile Battery. The
interior is divided into cells. Each cell contains a set of alternating
positive and negative plates called “electrodes” (See next page).
There is always one more negative plate - one on each end.
Separators are placed between each plate for insulation and the
set is immersed in an electrolyte such as sulfuric acid solution. An
automotive Battery has the same type of cells, however industrial
cells are much larger and more rugged to give longer operation and
increased capacity since their work load is greater.

BC-5
 BATTERY

Vent
Cap Plate Protector

Positive
Plates

Separators

Negative
Plates

Jar

Additional
Cells

BC-6
 BATTERY

Specific Gravity
The strength of the electrolyte is measured in terms of specific
gravity. This is the ratio of the weight of a given volume of electrolyte
to an equal volume of water. Concentrated sulfuric acid has a
specific gravity of about 1.835 and water has a specific gravity of
1.000. The acid and water are mixed in a proportion to give the
specific gravity desired. For example, electrolyte of 1.275 specific
gravity is about 27% concentrated acid and 73% water.

!! WARNING
• When mixing electrolyte, always pour acid into water.
Never pour water into acid. Never add acid directly to a
Battery.

The Chemical Reaction

In a fully charged cell, the electrolyte has a specific gravity that
varies from1.270 to 1.290. A discharged cell will have a specific
gravity between 1.150 and 1.160 (we recommend a Battery never
be discharged below 1.150). Specific gravity is a convenient way to
check the condition, state of charge, or energy stored in the Battery.
A storage Battery cell develops a voltage potential when any two
dissimilar metals are immersed in a suitable electrolyte. The two
metals used for electrodes in lead-acid cells are Lead Peroxide (Pb
03) for the positive plates and Sponge Lead (Pb) for the negative
(See Fig. 2). This result is a voltage potential of approximately two
volts per cell. This potential does not vary regardless of cell size.

Typically
2.06 Volts

Electrolyte
(Sulphuric Acid
and Water)

Maximum
Sulphuric Acid

Fully charged
Specific Gravity
1.270 to 1.290

Negative Plate Positive Plate

Sponge-Type Lead Lead-Type Peroxide

BC-7
 BATTERY

Less than 2.06 Volts

The Chemical Reaction (cont.)
During cell discharge, Lead Peroxide and Sponge Lead combine
with sulfuric acid to form Lead Sulfate (Pb S04) on both plates
(Fig. 3). This action decreases cell voltage as the two electrodes
approach being of the same chemical composition (Lead Sulfate). As
Decreasing
Sulphuric Acid the sulfuric acid is removed from the electrolyte solution, the specific
Increasing gravity of the electrolyte decreases and approaches the specific
Water
gravity of water (Fig. 4). The discharged cell will have an open cell
voltage potential of approximately 1.96 volts.
When charging current is applied to a discharged cell (Fig. 5) the
Lead Sulfate is broken up. The active materials are restored to their
Decreasing Decreasing
Sponge Lead Lead Peroxide respective plates and the electrolyte again becomes a sulfuric acid
Increasing Increasing solution. Cell voltage rises as the two elements become increasingly
Lead Sulphate Lead Sulphate different in composition. The specific gravity of the electrolyte
Figure 3 increases as more of the two elements are formed.
Once again, a fully charged cell is created. The positive electrode
Typically
is Lead Peroxide, the negative electrode is Sponge Lead and the
1.96 Volts electrolyte is a sulfuric acid solution.

Minimum
Sulphuric Acid

Maximum
Water

Minimum
Specific Gravity
1.130

Minimum Minimum
Sponge Lead Lead Peroxide
Maximum Maximum
Lead Sulphate Lead Sulphate

Figure 4

Typically
2.33 Volts

Battery Charger

Increasing
Sulphuric Acid

Decreasing
Water

Increasing Increasing
Sponge Lead Lead Peroxide
Decreasing Decreasing
Lead Sulphate Lead Sulphate

Figure 5

BC-8
 BATTERY

Trouble Diagnoses and Corrections

! CAUTION
• The following table lists only typical examples. To perform
an accurate diagnosis, carefully listen to the user’s
complaints and check the actual vehicle to fully understand
under what conditions the symptoms occur.
• Request battery maker to replace cells.

Trouble Condition Probable cause Corrective action

Short-circuited 1. Extremely low cell voltage • Short-circuited on bottom or • Replace faulty cell by single
and specific gravity during side part due to dropping of charged cell.
charging, discharging and active materials
electrostatic charging • Short-circuited due to
2. Low gassing during broken or holed separator
charging (Warping of plates due to
3. Excessive rise of repetition of overdischarging
electrolyte temperature will accelerate such fault.)
during charging • Short-circuited due to
4. Quick dropping of specific incursion of broken pieces
gravity after charging during fabrication of battery

Sulfation 1. Voltage and electrolyte • Repetition of overcharging • If the condition is in early

temperature are higher and discharging stage, remove the probable
during charging • Exposed plates in air for cause and carry on equation
2. Accelerated gassing a long time due to lack of charging.
during charging and electrolyte • Replace faulty cell by single
specific gravity not rising • Careless storage without charged cell if damage
to normal value additional charging cannot be remedied.
3. Quick dropping voltage • Use of battery at excessively
during discharging (Low high specific gravity
battery capacity)
• Excessive self-discharging
4. Whitened plates in due to incursion of impurities
extreme cases
Excessive self-discharging 1. Quick dropping of specific • Use of impure water other • Take daily care of battery.
gravity after charging than distilled water • Replace faulty cell by single
2. Considerably reduced • Incursion of impurities charged cell.
charging capacity • Too high specific gravity
• Electrolyte temperature high
• Insufficient cleaning of
container, leakage of
blocked fluid
Exchange of polarity 1. Exchanged polarity of • Due to quick discharge • Replace cell.
some cells in a battery without noticing the
during discharging or high extremely low capacity of
electrolyte temperature of some cells
some cells
2. Caused by emission of • Lack of necessary • Take daily care of battery.
gas due to dissolving of preparative means such as
electrolyte equation charge

BC-9
 BATTERY

Trouble Diagnoses and Corrections (Cont’d)

Trouble Condition Probable cause Corrective action
Other factors 1. Electrolyte color changed • Due to old battery corroded active • Check for voltage and specific
to brown dropped from fatigued positive gravity. If OK, use the battery for
plates and mixed into electrolyte the time being.
2. Smell of chlorine during • Sea water mixed into electrolyte • Replace electrolyte and charge
charging battery until chlorine smell
disappears.
• Replace cells.
3. Electrolyte excessively • Cracked battery cells • Find causes and follow proper
reduced • Excessively high electrolyte procedure to repair.
temperature during charging • Take proper measure for sulfation.
• Excessive sulfation
4. Excessively high electrolyte • Lack of electrolyte • Refer to each corrective action.
temperature • Shorted cells
• Reversed polarity
5. Heat from connector • Poor contact of connector with • Solder (Inquire with battery
portion binding posts maker).

The Battery has reached the end of its life if the following
phenomena appear. (Also take into account the Battery age and
operating conditions.):
• Electrolyte decreases fast and supplying frequency increases.
• Electrolyte temperature becomes 50°C (122°F) or more.
• Timer of charger cannot be turned OFF (or sometimes cannot
be turned OFF).
• There is greater variance in voltage and specific gravity among
cells.
• Electrolyte color changed to brown (emergence of PbO2
sediment in electrolyte).
• Electrolyte color changed to gray (high electrolyte temperature
causes Pb sediment and dropping).
• Specific gravity does not reach 1.250 or more even after
charging or equation charging is complete.

BC-10
 BATTERY MAINTENANCE

!! WARNING
EYE
PROTECTION • When working with any Battery, always wear protective
REQUIRED equipment, such as Rubber Gloves, Rubber Apron and
Protective Face Shield. No smoking at any time when
working near a Battery area.

Cleaning the Battery

The entire Battery, with its tray and connections, should be kept clean
and dry. This may be done by wiping with a wet cloth, blowing off with
air or washing with water depending on the nature and amount of
dust or other material which may accumulate on it.
EYE ! CAUTION
PROTECTION
REQUIRED • Do not use steam or hot water. Use only moderate
pressure of either water or air.
Electrolyte spilled on the bottom of cell covers, trays or Battery
compartment, never dries or evaporates. It causes grounds and
corrodes any metal parts that are subject to attack from sulfuric acid.
If the top of the Battery is damp with electrolyte or if electrolyte is
spilled, it should be neutralized by applying bicarbonate of soda
solution (one pound of soda to one gallon of water). For best results,
apply a warm solution. Wait until foaming action subsides and then
rinse off with clear water. The Battery and its compartment should be
washed each month, or when needed but no less than least twice a
year.
NOTE:
If a Battery is constantly wet, it may be due to overfilling, overcharging
or a cell is leaking.

!! WARNING
• Check all local, federal, and state regulations. The
water and solution used to rinse off the Battery may be
considered hazardous waste.
If dust is accumulated on upper surface of Battery, the dust can absorb
water and cause leakage between terminals. Periodically clean the
upper surface of the Battery with a wet cloth and dry it when inspecting
electrolyte level.

!! WARNING
• Never clean the upper surface of the Battery with a dry cloth,
dust it or put a vinyl cover on it. Any of these actions may
generate static electricity and cause Battery explosion.
• Never put fingers or driver into the Battery Connection. Never
touch the Connection Terminal of the Battery. It may cause
electric shock and short.

BC-11
BATTERY MAINTENANCE

! CAUTION
• Always clean the Battery before charging.
If dust is accumulated on upper surface of Battery, the dust can absorb
water and cause leakage between terminals. Periodically clean the
upper surface of the Battery with a wet cloth and dry it when inspecting
electrolyte level.

!! WARNING
• Never clean the upper surface of the Battery with a dry cloth,
dust it or put a vinyl cover on it. Any of these actions may
generate static electricity and cause Battery explosion.
• Never put fingers or driver into the Battery Connection.
Never touch the Connection Terminal of the Battery. It may
cause electric shock and short.

! CAUTION
• Always clean the Battery before charging.

Supplying Distilled Water

! CAUTION
• Fill distilled water up to the prescribed level on daily basis.
Further, it is recommended that distilled water always be
available.
• Never use or mix tap water. It may shorten life of the Battery
due to impurities such as chlorine, Fe (iron) and the like.
A certain amount of water loss in cells is normal. Check electrolyte
levels daily and replace water lost due to evaporation and electrolysis
occurring during the charging process. Never allow electrolyte levels
to drop below the top of the separator or plate protectors.
Keeping the electrolyte level within its proper limits is the most
important aspect of battery maintenance.

BC-12
BATTERY MAINTENANCE

Adding Water (Cont’d)

If the electrolyte is below the plates, add water to each cell only enough
to get the hydrometer reading before charging. Overfilling causes loss
of acid which reduces the Battery energy. Allow time for an electro-
chemical reaction to take place before taking a hydrometer specific
gravity measurement. If the electrolyte level is high enough to take a
hydrometer reading before charging, do not add more water or it may
overflow during charging. Use only approved tap or distilled water in
the Battery. In some geographical areas, tap water may contain harmful
impurities, which reduces Battery life. The normal water level varies
with the type of cell. Determine the level from the specific instructions
with each Battery. The following general rule applies with respect to
dimension “A” shown below.

E
A
B
F
C

Cell Height Dimension ‘A’

15” or less 1/8”
15” to 24” 1/4”
Over 24” 1/2”

B. Recommended Electrolyte level

C. Low Electrolyte level
D. Filler Tube
E. Plate Protector
F. Separator

The Hydrometer
Using a hydrometer and charging the Battery correctly are important
parts of any maintenance program. The hydrometer will give you the
specific gravity reading and is a convenient way to check the conditions
of the Battery. The correct charging methods, not undercharging or
overcharging, will help extend the life of the Battery.
First, make sure there is enough electrolyte in the Battery cells (See
‘Adding Water’). A high or low level can alter the hydrometer reading.
During the electro-chemical reactions taking place in the cell, there
is some loss of water. Water decomposes the hydrogen and oxygen
and forms bubbles which escape from the cell. Lost water effects the
concentration of sulfuric acid in the electrolyte. When the electrolyte level
drops by 1/8” the specific gravity will rise 3 to 5 points.
When reading a hydrometer, there must be enough liquid in the barrel
to permit the float to ride free. The float must not touch the side, top or
bottom of the barrel (see below).
Read the hydrometer at eye level with the electrolyte surface in the
barrel. A high Guage Float indicates a high specific gravity. Inversely, a
low Guage Float indicates a low specific gravity

BC-13
 BATTERY MAINTENANCE

Inspection
Specific Gravity
NOTE:
Specific gravity is very useful for determining battery life and
condition. Measure the specific gravity of each Battery Cell using a
Gravimeter.
1. Insert the Gravimeter into a Battery Cell. Depress and release
the Gravimeter Bulb to draw fluid into the device.

! CAUTION
• Read measurement with the Gravimeter remaining in
the Battery Cell. When pulling out the Gravimeter upon
completion, use extra care to prevent scattering of
Battery electrolyte outside the Cell.
2. Keep the Guage Float of the Gravimeter at eye level and read
the upper end portion of Battery electrolyte swollen due to
surface tension (meniscus).

! CAUTION
• If there is variance in specific gravity among cells,
perform equation charging and measure specific gravity
again. (For method of equation charging, refer to CS
section). If result shows big variance in specific gravity
among cells, battery has reached the end of its life.
(Battery life depends on years of use, conditions of use
and maintenance; equation charging may be necessary
several times depending on cases).
• If specific gravity is below 1.250 after charging, battery
has reached the end of its life.
• Carefully determine the battery life based on the above
Hydrometer Temperature Correction Chart
observation, together with advice by battery maker
personnel.
1.320

!! WARNING
(St) Specific gravity of Battery electrolyte measured at t°C

1.300

1.280
1.300
• Always wear Personal Protective Equipment when
(Sz0) Specific Gravity at 20°C (68°F)

1.260 checking fluid to reduce the risk of fluid contact.

1.280
1.240 3. When battery electrolyte temperature is other than 20°C (68°F),
1.260
1.220
convert specific gravity into temperature.
1.240
1.200 Sz0 = St + 0.0007 x t – 0.014
1.220
1.180
Sz0: Specific gravity of battery electrolyte at standard
1.200 temperature [20°C] (68°F)
1.160
1.180 St: Specific gravity of battery electrolyte measured at t°C
1.140
1.160 t: Temperature of battery electrolyte during measuring
1.120
1.140 When specific gravity converted into temperature is below 1.145,
1.100
1.120
immediately perform charging.
1.080
-20 -10 -0 10 20 30 40 50 60
NOTE:
(-4) (-14) (32) (50) (68) (86) (104) (122) (140)
(t) Battery Electrolyte Temperature Specific gravity at the time of charging end: 1.280 [electrolyte
temperature 20°C (68°F)]

BC-14
 BATTERY MAINTENANCE

Battery Temperature
The temperature of the electrolyte will affect the specific gravity
reading. As an approximation, it is known that every increase of
10 degrees F (5.6 degrees C) in temperature will lower the specific
20
gravity reading by about 3/1000th (0.003). The opposite is also true,
10
00
ten degrees lower will raise the specific gravity reading by 0.003.
90 Battery electrolyte temperature should not exceed 120 degrees F
80
(49 degrees C) or permanent Battery damage will occur. The center
70
60
cells of the Battery are usually the hottest. An eight hour cooling
50 time is recommended before charging. A cool Battery accepts the
40 correct charging rate. Electrolyte temperature above 120 degrees F
30 indicates a need to: 1) provide better ventilation for the Battery in the
truck; 2) check for higher than normal discharge rate or 3) provide
increased cooling time before charging. Recommended Battery
cycles includes: 1) eight hours working (Discharge); 2) eight hours
cooling and 3) eight hours charging.
The average or normal temperature reference point is when the
electrolyte is at 77 degrees F (25 degrees C). In a fully charged
state the electrolyte will give a specific gravity reading of 1.285 to
1.295 (no temperature correction). If the hydrometer being used is
not temperature correcting, a thermometer must be used. Special
Battery thermometers are available that incorporate the correction
factor directly and add or subtract the correct number of points.

Hydrometer Points Correction

Temperature ºF
Reading for Hydrometer
1.278 117 +12
1.281 107 +9
1.284 97 +6
1.287 87 +3
1.290 77 (Normal ref. cell) 0
1.293 67 -3
A
1.300
1.296 57 -6

1.280 B 1.299 47 -9
1.302 37 -12
1.260

C
1.240 The graph at left shows the degree at which specific gravity of
electrolyte diminishes as the Battery discharges.
Specific Gravity

1.220
A. 100% Discharge Limit
1.200 B. Recommended Discharge Limit
C. Do not recharge if specific gravity is above this line
1.180
D. Recommended discharge level for powered industrial trucks
1.160
D
Whenever in doubt as to how much a Battery has been discharged,
1.140 use the hydrometer.

1.120

1.100
0 20 40 60 80 100
Discharge Limit

BC-15
 BATTERY CHARGER

Charging The Battery

In order to recharge a storage Battery, it is necessary to pass direct
current through the cells in a direction that is opposite to that of
discharge current. The ampere-hours of charge must be equal to the
ampere-hour of discharge, plus a small excess to make up for the
losses. The additional amount varies depending upon the age of the
Battery and the electrolyte temperature, but the average is 12%.
Proper charging means returning the required number of ampere-
hours without gassing, over charging or raising the electrolyte
temperature over 120 degrees F (49 degrees C). In addition to
returning slightly more than was taken out, it is necessary that the
final 10 to 20% of the capacity be returned at a low rate. Any excess
amount of charging current at the end of the charge cycle results in
heating and excessive gassing of the Battery. Heating and excess
gassing cause loss of water and loss of active material from the
plates, which will substantially reduce Battery lift.

Types Of Battery Charges

Types of Battery charges fall into the following categories:
1. The Daily Charge - Is usually 8 hours long and will keep the
Battery fully charged if its discharge is no more than 80% of the
capacity.
2. Equalizing or Weekend Charge - This is a low rate charge and
is given only to ensure all cells reach full charge, with little or no
difference between cells. It is simply a continuation of the regular
charge by increasing the daily charging time by an additional 3
hours.
After an equalizing or weekend charge, a hydrometer reading of
the electrolyte specific gravity will become a true reading. Fig. 10
shows specific gravity characteristics during charge. Therefore, for a
specific gravity reading to show a fully charged battery life, it should
be taken only after an equalizing or weekend charge.
NOTE:
With the different types of Batteries (gel cell, flooded lead acid,
flat plate, glass mat, and tubular batteries), it is best to consult
your lift truck sales professional for the Battery that is best for your
application. Purchasing a Battery on price alone does not get the
best Battery for your needs.
1.300

1.250
Specific Gravity

1.200

1.150 1.150
Recommended
Minimum
Discharge
1.100
0 1 2 3 4 5 6 7 8 Level
Time (Hours)

Figure 10

BC-16
 BATTERY CHARGE INFORMATION

BATTERY CHARGERS
The off-truck type charger is a separate entity. The battery charger
may or may not be included with the truck.

!! WARNING
Determine the type of battery charger that is used for the
forklift you are using. Operate the forklift accordingly.
• Alternating current power source voltage will vary with
the area in which the forklift is used. Determine the local
voltage before attempting to charge the battery. Use the
A appropriate transformer tap on the battery charger
• Tap adjustment requires specialized knowledge and
expertise. (Off-Forklift type chargers only)
• Tap configuration must be set before battery charging.
B For full charging, select a time frame in which minimum
voltage fluctuation occurs, then select the appropriate
transformer tap. If the wrong tap is selected, over-
charging or under-charging will result. If you have any
questions, contact your Local Authorized Dealer.
• A current or over-current circuit breaker (A) (hereafter
referred to simply as breaker) must always be connected
to the AC power supply side of the battery charger.
• Always use charging equipment that is appropriate for the
forklift battery being charged.
• If multiple Off-Forklift type battery chargers are in use,
each battery charger must be equipped with its own
circuit breaker
• Alternating current requires high-capacity units. Set the
charging equipment power source to the appropriate
level.
• Specialized knowledge and expertise is required. For
information on the legal requirements of your country,
contact your Local Authorized Dealer.

BC-17
BATTERY CHARGE INFORMATION

BATTERY CHARGE CLASSIFICATIONS

Normal Battery Charge
The normal battery charge is used to restore the battery to its
original power level.
Equation Battery Charge
When the normal battery charge is applied many times, the voltage
level and the battery fluid specific gravity of the individual cells will
show a wide variation. This wide variation will prevent full charging
of the battery. Equation battery charge is used to equalize individual
cell voltage and battery fluid specific gravity and make full battery
charging possible again.
As a general rule, a battery charged and discharged on a daily basis
should have equation charging applied after every 10 or 15 charge/
discharge cycles.
Additionally, equation charging should be performed as soon as a
possible if any of the following conditions occur.
a. Battery discharge in excess of the specified limit.
b. Battery charging following discharge is delayed for an
extended time period.
c. A battery short circuit has occurred.
d. A battery that has not been used for an extended time period
is readied for use.

! CAUTION
• Equation battery charging is used to restore a battery to
its full potential. However, it should not be performed to
frequently. Frequent equation battery charging will result
in a greatly reduced battery service life.
NOTE:
• The battery consists of lead cells connected in series to another.
Each cell has a capacity of approximately 2 volts. There are
several dozen cells. The connected cells are contained in the
battery case. When there is significant variation in voltage and
battery fluid specific gravity between individual battery cells, full
charging will not be possible.
• With some battery charging equipment, equation battery
charging occurs automatically after some specified number
of charge/ discharge cycles. Manual selection of the equation
battery charging mode is not required.

BC-18
 BATTERY CHARGER INFORMATION

CHARGING PREPARATIONS
1. Move the forklift to the charging area and park it
2. Check the battery fluid level (refer to page 9). Replenish the battery
fluid with distilled water to just over battery plates if needed. Only
replenish to normal level after charging is completed and battery is
OFF cooled down.
3. Check that the circuit breaker on the AC power supply side is OFF.

!! WARNING
• During battery charging, large quantities of highly-explosive
hydrogen gas may be released from the battery. To minimize
the danger of an explosion, battery charging should be
performed in a well-ventilated area protected from direct
sunlight. Remove all objects that might ignite the gas from
the immediate area before beginning charging.
NOTE: (Off-Forklift type Battery charger)
Transformer tap selection is required before beginning charging.
Measure the charger power supply voltage. Select the appropriate
transformer tap.
Selection of the wrong tap will result in battery over-charging or under-
charging. Contact your Local Authorized Dealer if you require more
detailed information.

How To Charge Battery (Off-Forklift Type)

Charge the battery according to the manual supplied with the charger
being used.
1. Ensure the supply side voltage corresponds with the charger input
voltage.
NOTE:
The battery chargers are preset to the following input voltages at the
time of delivery:
110V ... 100-volt charger
220V ... 200-volt charger
440V ... 400-volt charger
2. If the charger input voltage does not correspond with the supply
voltage, the input side voltage is adjustable as follows using the
tap changer located inside the charger.
!! WARNING
• Unplug the charger before adjustment. Serious injury or
death can occur by electrical shock.
3. Connect the charger output plug to the battery plug.
Battery Connector

Charge Output
Plug

BC-19
BATTERY CHARGER INFORMATION

How To Charge Battery (Off-Forklift Type) (Cont’d)

! CAUTION
• Do not connect the charger output plug to the body
harness connection. The battery will not charge through
this connection.
4. Connect the charger input plug to the wall outlet.
• To prevent a short circuit, install a no-fuse breaker on the
wall outlet side (in the service shop) to connect the charger
input plug.
5. Push the NORMAL or EQUAL button to select normal or
equalizing charge, respectively.
When an equalizing charge is desired, press the EQUAL button to
set the charger in that mode. The NORMAL pilot lamp will go out
and the EQUAL pilot lamp will come on.
Make sure only the pilot lamp of the selected charging mode is lit.
At this time, charging will be started automatically.
NOTE:
• Push the NORMAL or EQUAL button for about 2 seconds. Do not
push it more than 5 seconds.
Valid for most chargers. Alway read and understand the
manufacturers instructions for the charger beign used.
• After charging is started, it is not possible to change the charging
mode (NORMAL or EQUAL). If it is necessary to change the
mode, stop charging (push the STOP button), and then select the
charging mode again.
• It is advisable to charge the battery using the equalize charging
mode at least two or three times a month.
6. While charging, the charge indicator lamp will come on
sequentially and remain lit. Firstly, the Initial (1st) lamp comes on,
then the 2nd lamp, and they remain lit. Finally, the Final lamp will
come on.
NOTE:
When the FINAL lamp comes on, the timer will activate, charging is
complete.
7. Shut off the charger and then disconnect it from the battery. Now
reconnect the battery to the truck.

Storing the Battery

• Be sure the Battery is fully charged before placing it in storage.

! CAUTION
• Before charging, add distilled water so electrolyte level is a
little higher than the prescribed level.
• When not in use, the Battery should be stored in cool, dark, well
ventilated location with low humidity. Check specific gravity from
time to time and, when it is below 1.200, charge the Battery.
Perform equation charging once every two months. The Battery
determines the functional life of a forklift. Be sure to record all Battery
maintenance work.

BC-20
 ONBOARD BATTERY CHARGER OPTION

Battery Charger Specifications

CC CV FLOAT
25A (+/- 3%)
25A 29V
28V (+/- 1.5%)
27V (+/- 1.5%)
20A 29V

Voltage
Current
15A 29V

10A 29V

5A MAX 1A (+/- 3%) 29V

Charge Time Amps

Volts

P6 P12

P1 P7

The fully charged condition has been achieved when, for a period
of two hours, the cell voltages do not continue to increase and the
charging current does not continue to decrease.
Pin (P) Specification
1 LED_GND *
2 LED_Power *
3 +24V GND Input
4 Inhibit Output
5 +24V Input
6 NC
7 Programming GND
8 Programming BGND
9 Programming Reset
10 Programming VDD
11 NC
12 NC

* LED Display Specifications

A. Charging - Flashing at 2Hz
B. Charging over 80% - Flashing at 5Hz
C. Fully charged *100% SOC) - Steady
D. Error / Warning - Flashing 3 times at 5Hz and then OFF for 1
second, repeatedly.
E. Charger not plugged into wall - OFF

Charger
Battery Capacity (Ah/5h) Input Voltage (V) Output Current (A) Output Voltage (V) Plug Type
Anderson 175
330 - 450 120 VAC, 60Hz 80 Max 28V
(Red)

BC-21
 BATTERY CHARGER INFORMATION

OPTIONAL ON BOARD CHARGING

This unit has an optional on-board charger, which can support
opportunity charging cycles and, depending on the battery, will move
through several charging stages finishing with a trickle charge.
The on-board charger is sealed from dust and moisture and built into
the truck frame.
A B As shown at left, a three prong standard US type NEMA 5-15 power
plug (A) is located on the dash for easy access using a 16-AWG
extension cord from any 120V AC power supply.

! CAUTION
• Do not use an extension cord longer than 25 feet.
A green charge indicator light (B) is located near the dash plug for visual
status of charging. The light will flash at various intervals while charging
is in progress and will remain illuminated when charging is complete.
!! WARNING
• Do not charge batteries or operate the charger in a trailer or
box car.
• Always park the unit in an assigned charging area.
• Lower the load carry to the floor.
• The Steer Tiller Handle should be in the vertical position
(brake on).
• Turn the ignition switch OFF.

USING THE ON-BOARD CHARGER

After truck is parked in an assigned charging area
• Ensure nothing prevents ventilation above the battery.
• Connect the extension cord to the charger plug on the dash
(shown on left).
• Plug the extension cord into a 110-120 volt wall outlet.

! CAUTION
• Ensure the extension cord is fully seated into the dash
charger plug.
• Ensure the Battery Connector is securely plugged into the
truck.
• Always ensure the extension cord is not in a traffic area
where it could be run over or damaged.
• Always ensure the extension cord does not pose a trip
hazard for pedestrians.
DURING CHANGING OPERATION (B)
(GREEN LED INDICATOR LIGHT)
• Charging - Flashing at 2Hz
• Charging over 80% - Flashing at 5Hz
• Fully Charged (100% SOC) - Steady green
• Error/Warning - Flashing 3 times at 5Hz and then off for 1 second,
repeatedly.
• Charger not plugged into the wall - OFF
• The truck cannot be powered while charging.

BC-22
OPTIONAL BATTERY PACK CARE AND MAINTENANCE

BATTERY OPTIONS
There are 3 battery options for the 2W7 pallet truck:
• Industrial battery: Normally requires the larger battery box on
load carry (9.8”, Max 300 aH).
Refer to pages BC-11 through 15 for Battery maintenance
procedures.
• WET Cell 171Ah (6-hr rate): Battery pack has 4, 6-volt
batteries with swing out upper trays for easy access
maintenance of water levels in all 4 batteries.
Batteries are rated in ampere-hours and are selected to perform
a specific work load in an established period of time. Increasing
the work load or time period could result in over discharging,
thus shortening battery life. Generally, all lead-acid batteries
should not be discharged to more than 80 percent of its six-hour
rated capacity.
Battery pack configuration under the cover shown at left. Lift
the spring-loaded Battery Release Lever to disengage the Top
Battery Trays for swing away access to the lower Batteries.
Refer to pages BC-11 through 15 for Battery maintenance
procedures.

• Maintenance Free (VRLA 195Ah, 6-hr rate): Battery Pack

has 4, 6 volt maintenance free batteries that are mounted in a
FIXED tray.
Being a low maintenance battery, little is required regarding
maintenance operations. The top of the battery should be kept
clean and dry and may be washed to remove any accumulated
foreign matter. In the unlikely event of accidental contamination
with electrolyte, wash with a neutralizing solution (or one gallon
of water mixed with one pound of baking soda). Follow with a
rinse using clear water. Always follow state and local regulations
for cleaning batteries.

! CAUTION
• Never attempt to add water to a maintenance free
Battery. It has been designed to function without any such
additions over its entire life. Any attempt to remove the
cover from the Battery shall void the warranty.

OPTIONAL BATTERY PACK

Battery and Battery Pack removal and installation are covered on
page BC-27.
NOTE:
The Battery Packs should not be discharged below 1.90 volts per
cell (80% Depth-of-Discharge).

BC-23
OPTIONAL BATTERY PACK CARE AND MAINTENANCE

!! WARNING
• Always wear appropriate safety equipment when working
around batteries.
• The wet lead acid & VRLA sealed battery can emit
hydrogen gases under some conditions. Charge in a well
ventilated area and keep open flames and sparks away
from batteries.
• Lift the battery pack with a hoist, crane, lift truck, or
similar equipment. Move batteries on trucks, conveyors,
or rollers. Make sure equipment is of ample strength and
properly installed before using.
• Disconnect the battery from the truck when performing
maintenance and repair on the motor or electrical system.
• Open, or “break” the battery circuit before attempting
repairs to the charging plug or receptacles.
• Familiarize yourself with the battery pack and procedures
for charging and handling. Contact a local representative
for information.
• Assign battery and charger care to properly trained
personnel.
• Review company safety regulations and familiarize
yourself with industry and government guidelines (OSHA,
ANSI, ect.) to help reduce personal accidents and
equipment damage.
• Do not mix old with new batteries.
• Use only batteries of the same size power rating, do not
mix.

BC-24
OPTIONAL BATTERY PACK PARTS DESCRIPTION

WET CELL PACK

16
9.5 - 12.5 (.96 - 1.27, 84 - 110) 5 6 15

11

4
7

10
9
20 - 28 (2 - 2.85, 177 - 247) 8
3

14
13
12 38 - 52 (336.3 - 460.2 in. lbs)

: Nm (in/lb)

Item Description Qty

1 Swing Out Battery Support Weldment 1
2 Battery Pack Tray (Left) 1
3 Battery Pack Tray (Right) 1
4 Hinge Top Mounting Block 1
5 Hinge Block Mounting Screw (M6-1.0 x 20) 2
6 Lock Washer (M6) 2
7 Battery Slide Latch 1
8 Latch Screw (M8-1.25 x 45) 1
9 Lock Washer (M8) 1
10 Flat Washer (M8) 1
11 Latch Spring 1
12 Battery Support Anchor Screw (M10-1.50 x 75) 1
13 Lock Washer (M10) 1
14 Flat Washer (M10) 1
15 Swing Out Battery Lock Bracket (EE option) 1
16 Lock Bracket Screw (M6-1.0 x 25) (EE option) 2

Wet Cell Battery Specification

6 Volt golf cart type batteries

Wet Cell
Ah Rated at 171 Amp @ 6 Hrs.

BC-25
OPTIONAL BATTERY PACK PARTS DESCRIPTION

MAINTENANCE FREE

6 38 - 52 (336.3 - 460.2 in. lbs)

4
3
1 2 38 - 52 (336.3 - 460.2 in. lbs)

: Nm (in/lb)

Item Description Qty

1 Maintenance Free Battery Support Weldment 1

2 Battery Support Anchor Screw (M10-1.5 x 140) 1

3 Lock Washer (M10) 1

4 Flat Washer (M10) 1

5 Maintenance Free Battery Lock Bracket (EE option) 1

6 Lock Bracket Screw (M8-1.25 x 20) (EE option) 1

7 Lock Bracket Nut (M8) (EE option) 1

Maintenance Free Battery Specification

6 Volt Deep Cycle VRLA

Maintenance Free
Ah Rated at 195 Amp Hr

BC-26
OPTIONAL BATTERY PACK PARTS DESCRIPTION

EE BATTERY PACK COVER

4
3

1 2

Item Description Qty

1 Battery Pack Cover 1

2 Insulator Sheet 2

3 Rivet 8

4 Sealed Cam Lock 1

NOTE:
Insulator Sheets must not be removed. If damaged, repair
immediately to maintain “EE” rating.

BC-27
OPTIONAL BATTERY PACK REMOVAL

BATTERY COVER REMOVAL

1. Remove the Battery Cover Hold-Down Knob.
2. Tilt the Battery Cover toward the fork side and lift it upward from
the Battery Compartment.

BATTERY PACK REMOVAL

! CAUTION
• Park the unit on a level surface.
• Ensure the lifting device is rated to lift the Battery weight.
Wet Cell
1. If the unit is equipped with an optional Backrest:
A. Remove the Upper Bolts on either side of the Backrest.
B. Loosen the Middle Bolts on either side of the Backrest and tilt
the top of the Backrest toward the forks.
3. Using a 17mm Socket Wrench, remove the Battery Tray Anchor
Bolt from the center of the Battery Tray Frame.
4. Connect a lifting device to the Battery Tray Center Lift Pin and
carefully remove the battery from truck.
Maintenance Free
1. If the unit is equipped with an optional Backrest, remove the
Backrest. (refer to Section BF)
2. Using a 17mm Socket Wrench, remove the Battery Tray Anchor
Bolt from the center of the Battery Tray Frame.
3. Connect a lifting device to the Battery Tray Center Lift Pin and
carefully remove the battery from truck.

INDUSTRIAL BATTERY REMOVAL

! CAUTION
• Park the unit on a level surface.
• Ensure the lifting device is rated to lift the Battery weight.
1. If the unit is equipped with an optional Backrest:
A. Remove the Upper Bolts on either side of the Backrest.
B. Loosen the Middle Bolts on either side of the Backrest and tilt
the top of the Backrest toward the forks.
2. Connect a lifting device to the Battery and carefully remove the
battery from truck.
NOTE:
When re-installing the Battery, adjust the Battery Gates whereas
the Battery will have no more than 1/2” of horizontal movement as
required per UL583 for North America units.

BC-28
MEMO

BC-29