Check specific gravity and electrolyte levels in each cell
Adjust electrolyte levels as necessary
Check voltage in each cell
Check for positive and negative voltage leaks to machine
Inspect all lead straps and cable connections
Inspect sealing compound
Provide all test results in writing
Inspect all battery stops and battery locks and latches
Inspect truck and charger connector for proper connection to battery connector
Annual Battery Charger Service
Check A/C voltage input and DC voltage output
Check ammeter calibration
Inspect rectifiers and transformers
Visual inspection of all connections
Air clean inside of charger
Inspect cable for damage
Daily Procedure for Battery Maintenance/Charging
A normal cycle for a battery is 8 hours of work, 8 hours of charge, and 8 hours of rest (cool down).
Usually every 5th charge should be an equalizing charge. This should serve to bring all cells up to a 100% charge state. If this is not done, you may have premature cell or battery failure.
Before a battery is put on charge:
Electrolyte levels should be checked in each cell.
If no electrolyte can be seen, water should be added just enough until you can see liquid in each cell. (Do this only to prevent damage to the plates. Normal watering is done after charge, but you do not want to begin charging a dry cell.)
Replace the vent caps before charging.
After a battery has been charged:
Recheck electrolyte levels.
Fill to no more than 1/4 to 1/2 inch above the splash guard as overfilling causes acid loss. Acid loss means capacity loss, cell imbalances, high heat, and premature battery failure.
If you notice any problems with a battery or battery damage, promptly notify Allstar Lift Trucks to prevent extended abuse and minimize repair costs.
A battery is 80% discharged when the specific gravity is 1.170.* A battery is 100% discharged when the specific gravity is 1.140.* At the 80% discharged level, the battery should be taken out of service and recharged, unless it is extremely hot – in which case it needs to cool down before recharge. *These figures are general rules of thumb.
A battery is fully charged when the specific gravity reaches 1.285 to 1.295.
Always charge battery in well vented area.
Never allow smoking, flames on sparks in battery area while charging is in process.
Shield eyes from explosive gases.
Sulfuric acid (battery acid) is poison and can cause blindness and severe burns.
Never unplug charger from battery while charge is in process to prevent electrical spark. Turn off charger then unplug cables.
Visual inspection of battery and charger cables for cuts or damaged insulation before use to prevent electrical spark.
If you are unsure about something call Allstar Lift Trucks’ knowledgeable service department and ask your question, we are always happy to assist you.