Hyster 2240 SRM 1 User manual

INDUSTRIAL BATTERY
ALL ELECTRIC LIFT TRUCKS
PART NO. 899648 2240 SRM 1

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
•When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity
to support the weight of the load.
•Donotliftheavypartsbyhand,usealiftingmechanism.
•Wear safety glasses.
•DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric
lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
•Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
•Keep the unit clean and the working area clean and orderly.
•Use the correct tools for the job.
•Keep the tools clean and in good condition.
•Always use HYSTER APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
•Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force
to remove parts.
•Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the
unit needs repairs.
•Be sure to follow the WARNING and CAUTION notes in the instructions.
•Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and
when working on these fuel systems.
•Batteries generate flammable gas when they are being charged. Keep fire and sparks away from
the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this
manual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in
death or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in
minor or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.

Industrial Battery Table of Contents
TABLE OF CONTENTS
General ............................................................................................................................................................... 1
Lead-Acid Batteries ........................................................................................................................................... 1
Specific Gravity.................................................................................................................................................. 2
Chemical Reaction in a Cell .............................................................................................................................. 2
Electrical Terms ................................................................................................................................................. 3
Battery Selection................................................................................................................................................ 4
Battery Voltage .................................................................................................................................................. 5
Battery as a Counterweight .............................................................................................................................. 5
Battery Ratings.................................................................................................................................................. 6
Kilowatt-Hours .............................................................................................................................................. 6
Battery Maintenance ......................................................................................................................................... 6
Safety Procedures .......................................................................................................................................... 6
Maintenance Records .................................................................................................................................... 7
New Battery................................................................................................................................................... 7
Cleaning Battery ........................................................................................................................................... 7
Adding Water to Battery ............................................................................................................................... 9
Hydrometer.................................................................................................................................................... 10
Battery Temperature..................................................................................................................................... 10
Charging Battery........................................................................................................................................... 11
Types of Battery Charges.......................................................................................................................... 12
Methods of Charging................................................................................................................................. 13
Troubleshooting Charger .......................................................................................................................... 14
Knowing When Battery Is Fully Charged ............................................................................................... 14
Where to Charge Batteries............................................................................................................................ 14
Equipment Needed.................................................................................................................................... 14
Battery Connectors........................................................................................................................................ 15
Battery Care .................................................................................................................................................. 15
This section is for the following models:
All Electric Lift Trucks
©2008 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"
HYSTER
APPROVED
PARTS

2240 SRM 1 Lead-Acid Batteries
General
This section describes how to select and do the main-
tenance for large batteries used in electric lift trucks.
This information is for service personnel that must
do the maintenance on large lead-acid batteries. Bat-
tery repair requires special training and equipment.
Do not try to repair a battery unless you have the cor-
rect tools, equipment, and experience. Most battery
repairs are done by a special repair service. Some
batteries have a nameplate attached to the face of the
battery cover. This nameplate communicates specific
information about the battery including the name of
the battery manufacturer, battery type, serial num-
ber, nominal voltage, capacity in amperes at the five-
hour rate, and service mass (with ballast if used to
compensate for lack of battery mass).
Lead-Acid Batteries
A lead-acid battery converts chemical energy into
electrical energy. See Figure 1. Chemical changes
within the battery give the electrical energy. When
the chemical reaction has occurred so the battery
will not give its rated voltage and current, the bat-
tery is discharged. A reverse chemical action must
occur so the battery can be used again. The batteries
described in this section can be charged again by an
electric voltage and current from an outside source
so there is a reverse chemical action. The lead-acid
chemicals store the electric energy until the electric
energy is needed to operate an electric device.
Figure 1. Lead-Acid Industrial Battery
A lead-acid battery is made from several lead-acid
batteries called cells. Each cell has positive and
negative plates with dielectric spacers between each
plate. All of the plates are within a solution of
electrolyte. See Figure 2.
1. VENT AND FILL
CAP
2. POST
3. POST SEAL
4. PLATE
PROTECTOR
(SHIELD)
5. POSITIVE PLATE
6. EXPANS ION M ATS
7. RETAINER
8. SEPARATOR
9. NEGATIVE PLATE
10. BATTERY JAR
Figure 2. Battery Cell
1