Traction Battery

Traction Battery is the energy tank and is the counter weight of the electric lift truck. Minimum capacity is always recommended by the truck maker with the choice of larger capacity that can be fitted into the battery compartment. It is the most costly part on the truck but advisable to select the biggest capacity because:

1. Minimum recommended capacity may cannot complete the duty when the heavy or continuous operation is come to involved.  So the larger capacity is needed in order to avoid over discharged.
2. Efficiency of the Battery as well as the truck itself will automatically drop down after they have been put into the Service. So the larger capacity is recommended to avoid even one time over discharged unless the Spare Traction Battery is there.
3. Maximum efficiency of the Traction Battery is depends on correct use and:
   • Capacity of the Battery.
   • Type of Attachments
   • Frequency of Charging. More often more shorten the lift time.
   • Charging equipment.
   • Maintenance.
   • Number of battery per truck.

Spare Battery

When two shifts operation is there, then two (2) batteries is needed for each truck. Because one battery is on working and other one is on rest after full charged.

If three shifts operation is there, then three (3) batteries is needed for each truck. Because one battery is working on truck while the other two is on charging and/or resting after full charged.

Battery Maintenance

In short, please care following:

1.  Always keep the Battery clean and dry.
2.  Flame and Smoke are prohibited during charging and operating.
3.  Not allow the foreign matter entering into the cells.
4.  Keep all connector always tight.
5.  Not allow any metal, even with insulator, rest over the cells.
6.  Avoid even one time over discharged. This will shorten battery life dramatically.
7.  Top up with the distilled water only.
8.  Top up just slightly above the separator in each cell.
9.  Do not top up too much above the separator, just slightly above the separator is O.K, in order to avoid the acid spill out during do the charging.
10.  Do not use distilled water from metal container.
11.  Top up before charging and do not overfill. (Top up may need after 10-14 shift)

Charging:

• Each truck need one charger.
• Do not smoke or allow naked flame near the battery.
• Do charge Battery when the Battery fully discharged only, if possible.
• No charge is needed if No Work is in next day and when the S.G. is still 1.220 or higher.
• If battery is in over discharged state, do the charge as soon as possible within a day.  Over charging cooks the battery and shorten its life dramatically.
• Top up every cell, just slightly above the separator (DO NOT OVER FILL), and Cool down the battery before start charging.
• Record the Voltage and Hydrometer reading every cell BEFORE and AFTER charging.
• Temperature of the Pilot cell must not over 50 ºC during charging.
• Before charging, hydrometer reading should not below 1.140
• In order to assist the ventilation, do charge with the battery tray lid open but always keep the vent plugs closed in its place.  
• Apply equalizing charge when necessary.
• Cool down battery before put back to service.

Do:

1. Do:  Charge the battery daily after the shift unless the battery has been lightly discharged, or No Work is expected in next day and if the S.G. is still there at 1.220 or above.
2. Do: Daily check the level of the water. (Even top up may need after about 14 shifts)
3. Do: Allow the battery cool down before start charging.
4. Do: Lift up the battery compartment lid where possible when do the charging to assist ventilation.
5. Do: Keep the vent plug always closed when the charging do.
6. Do: Use the distilled water only.
7. Keep all connections and bolted terminals tight and filmed with petroleum jelly, if necessary.
8. Do: Check the charging plug, socket and cable for wear and tear and burning of contacts.
9. Do: Keep the battery and tray clean and dry at all times.

Don’t:

1. Don’t allow the battery in wet and dirty.
2. Don’t over top the cells. This will caused the acid spill out during work and charging.
3. Don’t allow the battery water below or same level to the separator.  This will damage the separator and seriously shorten the battery life.
4. Don’t over discharging.  This will caused the battery life shorten dramatically.
5. Don’t over charge by re-charging more frequently or longer period when you found S.G. of some cell not picking up.  It is better to replace the new cells.  Over charging will cooks the battery and shorten the life time dramatically.
6. Don’t remove the vent plug when do the charging.
7. Don’t use the jug to dispense the water or acid.  This will caused the battery wet and dirty.
8. Don’t use the water or acid from the metal container to top up the cell.
9. Don’t allow any impurity goes into the cells.
10. Don’t add the concentrate acid to the cells.
11. Don’t tamper with the battery or charger.  Any setting or fixing should be undertaken by qualified personnel.

SAFETY

• Do not smoke or use naked flame near battery.
• Wear gloves, goggles and shoes.
• Do not wear watch or jewelry.
• Always use insulated tools and do not rest the tools or any metal on the battery.
• Use only rightly matched Charger.
• Keep battery cover open with vent plugs in place when charging the battery.
• Charge batteries in well ventilated space.
• SWITCH OFF Charger before connecting AND disconnecting battery.
• Ensure that BATTERY and CHARGER Connector-Socket colors are same before connecting them. No wear and tear or burning of any contacts.
• Lift battery only by the lifting-holes provided, keep battery vertical and secure battery position properly.
• Preferably recharge battery at end of shift when discharge is complete.
• Preferably recharge battery at end of shift if the remaining power is not good for next incoming work.
• If acid is spilt---
  • On floor:Neutralize with an alkali like: Sodium Carbonate or  Sodium Bicarbonate powder
  • On Clothes:     Wash out with plenty water.
  • On Body:        Wash immediately with plenty of running water.

*If Acid is accidentally splashed into eyes: Wash thoroughly with a big lot of running water and immediately seek medical attention.

IN SHORT:

• THE BATTERY MUST BE CLEAN AND DRY, TOPPED-UP AND CHARGED.
• IT SHOULD BE ON A ROUTINE MAINTENANCE SCHEDULE.
• THIS WILL IMPROVE RELIABILITY, EFFICIENCY AND EXTEND BATTERIES LIFE.