Crown Battery 160S

Warning: This procedure requires trained personnel!

Enter the current battery charge in amperes

If the charger is rated higher than the connector on the battery, proceed with the following steps

Are dual intercell connectors present?

Is battery recording device present?

- A certain amount of water loss is normal in all batteries and it should be replaced with "pure" tap or distilled water. In some areas around the country, tap water may contain chemicals or other impurities harmful to batteries. If water is needed, add just enough to bring the electrolyte to the proper level. Batteries should be filled only at the end of the charging cycle

- Overfilling is the most common error made when watering and it can cause tray corrosion. Since tray corrosion can cause extensive damage to batteries and vehicles, extreme caution must be taken to avoid overfilling the batteries

- Motive power battery trays are mostly made of steel that is protected with an acid resistant coating

Regardless of how good the coating is, if a break in the coating exposes the steel tray to sulfuric acid spilled from the battery, the acid will corrode the tray. How quickly the tray corrodes depends on how much and how often acid is spilled on top of the battery and how often the battery is cleaned

- The major cause of tray corrosion is overwatering or overfilling a battery. When overfilled, the electrolyte will spill on top of the battery. Although the water in the electrolyte will evaporate, the highly concentrated acid solution remains and gives the appearance of dampness. If the acid is not removed, the tray will eventually corrode

- To prevent corrosion, batteries should be cleaned any time the accumulation of dampness or acid becomes significant

- A good technique to follow while watering batteries is to use a flashlight focused on the vent hole being watered. Visually watch the electrolyte level rise and stop watering the instant the proper level is reached

- Each cell is filled the same way. Cell filling equipment that automatically fills batteries to the proper level is available

Each cell of a battery has slight differences in uniformity of construction and content. These differences cause some cells to take less charge than the other cells in the battery. After a while the state of charge of the cells, which require more charge than the others will drift back in capacity and the battery will not deliver its full capacity

To bring the cells with a lower state of charge up to the same level as the others, the battery is given an "equalizing charge". The cells with a higher state of charge will be somewhat overcharged in order to bring the cells with a below normal state of charge up to full charge

The recommended frequency of equalization is dependent upon how often the batteries are cycled and the depth of the cycles. The frequency of equalization can dramatically affect the operational costs of the vehicle

Unnecessary equalizing charges, in addition to consuming electricity, can result in significant loss of battery life caused by overcharge. The following examples will give you a good idea of a reasonable battery-equalizing schedule for a specific battery operation

1. For batteries that are cycled only once or twice a week to an average depth of 30%-60%, a monthly equalizing charge is sufficient to keep them fully charged

2. Batteries that are discharged regularly- three or more cycles per week and to an average discharge depth of 60%-80% of their rating- can be kept healthy by equalizing them every two months

3. Batteries that are cycled four to eight times a month at any dept require equalizing about every month to keep them in a healthy condition

4. Batteries that are cycled five or more times a week at an average discharge of 60%‐80% may not need equalizing charges unless stored;

- A capacity test enables you to determine the capacity a battery actually delivers as compared to its rated capacity. This test can help determine if a battery should be repaired or replaced. When a battery delivers less than 80% of its rated capacity, the remaining capacity will decrease with each additional cycle

- It should be replaced before its cells fail and cause low-voltage operation of the vehicle, which can cause damage to the trucks electrical system

- A capacity test is performed by discharging a fully charged battery at a fixed rate (see chart on page 30) while monitoring specific test conditions, methods and procedures

- The six-hour rated discharge time is based on an electrolyte temperature of 77°F (25°C). Any deviation to that temperature, a correction to the six-hour rated time must be made

PROCEDURES FOR CAPACITY DISCHARGING:

1) Battery must be fully charged.

2) Specific gravities must be at manufacturers specifications, otherwise they must be adjusted accordingly.

3) Battery should be allowed to cool down prior to testing. Ideally, the temperature should be 75°F to 85°F. Otherwise the voltages will be affected by the temperature and the capacity must be temperature corrected.

4) Battery should be discharged within 24 hours of completion of charging and acid adjustment.

CAUTION: ONLY EXPERIENCED PERSONNEL SHOULD ATTEMPT BATTERY REPAIRS!

BEFORE PERFORMING ANY REPAIRS, REMOVE THE BATTERY FROM THE LIFT TRUCK. ALWAYS WEAR SAFETY GLASSES AND A FACE SHIELD WHEN WORKING ON OR NEAR BATTERIES

Is the repair person experienced?