SkyTrak 6036 Service Manual - Manual (Page 284)

Section 10. Electrical System
10-22 Model 6036/6036T S/N 9B0500 thru 14833
Fig. 10.15 Typical Hydrometer Operation
GREEN DOT DARK CLEAR
65% OR ABOVE
STATE OF
CHARGE
BELOW 65 %
STATE OF
CHARGE LOW LEVEL
ELECTROLYTE
MA1201
10.6.2 Batteries
All lead-acid batteries generate hydrogen gas
which is highly flammable. If ignited by a spark
or flame, the gas may explode violently,
causing spraying of acid, fragmentation of the
battery, and possible severe personal injuries.
Wear safety glasses when working near
batteries. In case of contact with acid, flush
immediately with water.
a. Description
The batteries supply power to the starter and
ignition systems to crank the engine. They supply
the extra power required when the electrical load
requirements of the forklift exceed the supply from
the charging system in case of a alternator or
charging failure, and acts as a voltage stabilizer in
the electrical system, smoothing out or reducing
temporarily high voltage.
With the correct cables properly attached, and with
the batteries properly mounted, the batteries never
need periodic maintenance.
When starting the forklift, crank for a maximum of
15 seconds, then rest for two minutes to avoid
burning up the starter. Do not idle excessively.
Keep the batteries from freezing by maintaining a
full charge. A completely discharged battery will
freeze at 18 °F (8 °C).
Water never has to be added to the batteries.
There are no filler caps. Each battery is sealed,
except for small vent holes in the cover. The
vents allow what small amount of gasses that are
produced in the battery to escape. The special
chemical composition inside the battery reduces
gassing to a very small amount at normal charging
voltages. Besides reducing gassing, the special
chemistry greatly reduces the possibility of over-
charge damage.
The vents require keeping the battery in an upright
position to prevent electrolyte leakage. Tipping
the battery beyond a 45° angle in any direction
can allow a small amount of electrolyte to leak out
the vent hole.
DO NOT exceed this 45° angle when carrying or
installing a battery.
Evidence of electrolyte leakage does not neces-
sarily mean a battery is defective.
Warning !
The battery has top post terminals. Securely
tighten clean cable clamps to the posts. Grease
or special spray sealers may be applied over the
connections.
b. Visual Inspection of a Battery
Inspect for damage such as a cracked or broken
case or cover that could permit loss of electrolyte.
If obvious physical damage is noted, replace
battery. Handle the battery with care. Determine
cause of damage and correct as needed.
c. Built-In Hydrometer
A special temperature-compensated hydrometer
is built into the cover of each battery to show at a
glance the battery’s state-of-charge. The hy-
drometer has a green ball within a cage which is
attached to a clear plastic rod; refer to Fig. 10.15.
It is important when observing the hydrometer that
the battery have a clean top to see the correct
indication. A flashlight may be required in some
poorly lit areas.
IMPORTANT: Always look straight down when
viewing the hydrometer.