East Penn’s Recommen e Gui e
to Lithium Battery Maintenance
MOTIVE POWER BULLETIN
OVERVIEW:
Ov r th cours of th R ady Pow r's lif , a minimum of r gularly
sch dul d maint nanc is imp rativ to achi v p ak p rform-
anc , r liability, lif , low st lif cycl costs, and to optimiz th
valu to th custom r. This docum nt has b n pr par d to illus-
trat wh n and what r gularly sch dul d maint nanc is n d d,
what data should b m asur d, r cord d, and analyz d.
PURPOSE:
By monitoring th batt ry for prop r r charging, prop r
discharging, and maintaining th batt ry, should any valu s b
out of sp cification, corr ctiv actions can b impl m nt d to
minimiz any n gativ impact on ov rall batt ry lif . This will
improv custom r satisfaction, productivity, and valu .
BATTERY MAINTENANCE GUIDELINES
Day 1 - Battery receipt an preparation
• R mov th prot ctiv wrap or bag from th batt ry along
with any banding mat rial; plac in r cycling contain r(s).
• Visually insp ct cabl s, conn ctors, tray for damag ,
xpos d conductors
• Insp ct th Batt ry Discharg Indicator (BDI) or Us r
Int rfac Modul (UIM) for any damag to th d vic or
wiring harn ss.
• V rify th batt ry w ight m ts or xc ds truck minimum
count rw ight r quir m nts
• Using approv d lifting d vic s, lift th batt ry ass mbly
from th pall t, and install in th truck.
• Conn ct th wiring harn ss from th R ady Pow r to th
BDI or UIM (as quipp d to th truck) and v rify prop r
op ration
– Th BDI or th UIM has a cabl that n ds to b rout d in
th truck; installation of th s d vic s ar s parat from
th purchas pric of th batt ry. This routing might b
provid d by th local forklift truck d al r.
– If th truck is quipp d with th capability of th Batt ry
Manag m nt Syst m (BMS) to communicat with th
truck's BDI, conn ct th wiring harn ss according to th
instructions in th R ady Pow r Installation and Op rating
Manual. Th truck must b compatibl with th corr ct
softwar "R v" to prop rly op rat ; this might b provid d
by th local forklift d al r.
• Conn ct th diagnostics harn ss to th R ady Pow r com-
munication from th t chnician's comput r and v rify th
curr nt softwar r vision is install d and op rating prop rly.
Day 1 - Battery receipt an preparation (cont’ )
• R vi w th charg r's s tting and validat it is to th custom r
sp cifications with th curr nt softwar packag .
• Conn ct th batt ry to th charg r, m asuring th DC amps
output, v rify it is to sp cification, and fully charg th batt ry.
FOLLOWING A PROPER
MAINTENANCE PROGRAM
East P nn und rstands that today's batt ry and charg r fl ts ar
significant corporat ass ts. With such an inv stm nt, nsuring
r liability is paramount. Prop r initial insp ction and r gular
pr v ntativ maint nanc will provid b n fits in many ar as:
• Achi ving p ak batt ry capacity
• Exp ri ncing long r lif which r sults in low r cost-p r-cycl
and AH
• Providing th ov rall low st Total Cost of Own rship (TCO)
• Maximizing day-to-day capacity, incr asing r liability, and
valu to th custom r
KEY INTERVALS FOR PRACTICING
ROUTINE MAINTENANCE
Onc th batt ry is in s rvic , it is v ry important to practic
a routin and sch dul d maint nanc program at s v ral k y
int rvals:
Daily Maintenance
• Visually insp ct th R ady Pow r cabl s, conn ctors, wiring
harn ss, and tray for damag , xpos d conductors, and
cl anlin ss of th batt ry and addr ss as n d d. Visually
insp ct th truck conn ctor and batt ry compartm nt;
cl aning or r pairing as n c ssary.
• V rify th charg r output is at sp cifi d amp rag .
• Monitor charg rs for fault conditions at th nd of charg .
Weekly Maintenance
• Visually insp ct th R ady Pow r cabl s, conn ctors, wiring
harn ss, and tray for damag , xpos d conductors, and
cl anlin ss of th batt ry and addr ss as n d d. Visually
insp ct th truck conn ctor and batt ry compartm nt;
cl aning or r pairing as n c ssary.
• V rify th charg r output is at sp cifi d amp rag .
• Monitor charg rs for fault conditions at th nd of charg .
• V rify th batt ry has r c iv d a full charg .
