Battery Maintenance

EP25-35(C)N Service Manual
7 Battery maintenance
WARNING
Always keep the battery of the truck clean and dry to prevent tracking currents. Cleaning
of the battery must be done in accordance with the instructions of the manufacturer.
Any liquid in the battery tray must be extracted and disposed of in the prescribed
manner. After cleaning, repair all damages to the insulation of the tray to prevent tray
corrosion and to ensure that the insulation value complies with the standard
EN 62485-3.
If the battery is taken out of service for a longer period, make sure that the battery is
fully charged and store it in a dry, frost-free room. The storage time should be taken into
account when considering the lifetime of the battery.
In case of any malfunctions on the battery or in the charger, contact the battery
manufacturer without delay.
When using motive batteries and chargers, always make sure you follow the current
standards, laws, rules and regulations in force in the country of use.
For batteries according to the ATEX directive 94/9 EC, the instructions for maintaining
the appropriate protection class during operation must be complied with (see the
relevant certificate).
Batteries marked with this sign must be recycled.
Batteries that are not marked with this sign are not returned for the recycling process
and must be disposed of as hazardous waste.
Copyright © 2016 by MCFE. All rights reserved. Revision: B Document ID: 624632 311 (700)
7.1 Safety regulations concerning the handling of lead-acid

batteries
Pay attention to the operating instructions of the battery and fix them close to the battery.
Work on batteries must be carried out by skilled personnel only!
Use protective glasses and clothes when working on batteries.

Pay attention to the accident prevention rules as well as the standards EN 62485-3 and EN
50110-1
No smoking!
Do not expose batteries to naked flames, glowing embers or sparks, as it can cause the battery
to explode.
Acid splashes in the eyes or on the skin must be washed immediately with water.
In case of an accident, consult a doctor immediately!
Clothing contaminated by acid must be washed with water.
Risk of explosion and fire, avoid short circuits!

Metal parts of the battery are always live. Do not place tools or other metal objects on the
battery!
Electrolyte is highly corrosive.
Batteries and cells are heavy.

Ensure secure installation. Use only suitable handling equipment, for example lifting gear in
accordance with the standard VDI 3616.
Dangerous electrical voltage!
Pay attention to the hazards that can be caused by batteries.
7.2 Battery maintenance
7.2.1 Daily maintenance
Charge the battery after every discharge.
For batteries with electrolyte circulation, check the electrolyte level towards the end of
the charging and, if necessary, top it up to the specified level with distilled water
according to the instructions of the manufacturer. The electrolyte level must not fall
below the anti-surge baffle, the top of the separator or the electrolyte minimum level
mark.
For batteries with filling level sensors, check the illuminated display daily. If the display
is green, the level is OK. If the display shows a blinking red colour, the filling level is too
low.
For batteries with float indicator in the water filling plug, make sure that the white
indicator is on the height of the window.
For batteries with standard vent plugs, open the plug and visually inspect the electrolyte
level.
When watering level is low, top it up with demineralized water at the end of the charge.
7.2.2 Weekly maintenance
After charging, look at the battery for signs of dirt or mechanical damage to the
components of the battery. Pay special attention to the battery charging connectors and
cables. In special cases when charging with an IU characteristic curve, also an
equalizing charge must be carried out.
7.2.3 Monthly maintenance
At the end of the charge, measure and record the voltages of all cells or bloc batteries
with the charger in the ON position.
After the charging is completed, measure and record the electrolyte density, electrolyte
temperature and the filling level (when filling level sensors are used) of all cells. If there
are any significant changes compared to earlier measurements or differences between
the cells or bloc batteries, charge the battery fully and allow it to rest for the minimum of
2 hours. If the problem persists, contact the battery manufacturer.
Before you talk to the battery manufacturer, measure and record:
 Total voltage
 Voltage per cell
 If the voltage readings are irregular, also check the specific gravity of each cell.
7.2.4 Annual maintenance
The insulation resistance of the truck and the battery are measured in accordance with
the standard EN 1175-1 at least once per year. The insulation resistance of the
disconnected, filled and charged traction battery mounted on the truck must be at least
50 Ω multiplied by the nominal voltage of the truck system between the live parts and
the frame of the truck.
For batteries fitted with an electrolyte circulation system, check the filter of the air pump
and clean or replace it, if necessary. It is possible that the filter must be replaced earlier
than expected if there are no leaks in the air pipes, but for some reason the defect
signal of the air mixing system on the charger or on the battery (on the DC air pump or
remote signal) is illuminated.
During annual maintenance, also check the correct operation of the air pump.
7.2.5 General maintenance
Keep the battery clean and dry to prevent tracking currents. Do the cleaning of the
battery according to the ZVEI code of practice, see section 7.2.8.
If there is liquid in the battery tray, remove it and obey an approved procedure to
discard it. Repair damage to the insulation of the tray after you have cleaned the tray.
Thus you can make sure that the insulation value is in accordance with EN 62485-3 and
that you do not cause corrosion to the tray. If you must remove cells, contact the battery
manufacturer.
7.2.6 Storage
If you remove a battery from service for a long period of time, make sure that:
 The battery is fully charged.

 The storage is dry and frost-free.
To make sure that the battery is always prepared for operation, you can select one of
these charging procedures:
 Do the equalizing charge monthly.

 Do float charging at a charging voltage of 2.23 V × the number of cells.
Count the storage time, when you think about the life of the battery.
7.2.7 Malfunctions
If you find malfunctions in the battery or in the charger, contact the battery manufacturer
immediately.
7.2.8 How to clean batteries
The instructions that follow are in accordance with the ZVEI code of practice.
It is important that you keep the battery clean. A clean battery:
 Can prevent accidents.

 Is less likely to become damaged.
 Is less likely to become damaged by corrosion or tracking currents.
 Has a long life and operating time.
The insulation resistance of the disconnected, filled and charged traction battery
mounted on the truck must be at least 50 Ω multiplied by the nominal voltage of the
truck system between the live parts and the frame of the truck in accordance with
EN 1175-1.
Dust on batteries can cause tracking currents that can lead to self-discharge of the
battery. If there is a flow of higher tracking currents, electrical sparking can occur and
there is a risk of explosion of the charging gas.
General instructions for battery maintenance:
 Use protective eyewear and protective clothing.

Make sure that the surface resistance of your safety clothes, boots and gloves is
≤ 108 Ω to prevent a build-up of static electricity.
 Do not use dry cleaning cloths to clean the battery.
Instructions for how to clean vehicle traction batteries:
 Before you clean the battery, remove the battery from the vehicle.
 Make sure that you collect the rinsing water that contains electrolyte and discard it
in a correct procedure.
When you discard used electrolyte water or rinsing water, refer to the instructions
for health and safety at work, accident prevention and how to discard water and
waste.
 Do not remove or open the cell plugs. See the instructions of the manufacturer.
 Clean the plastic parts of the battery, especially the cell containers, with a cleaning
cloth and clean water. Do not use cleaning agents.
 After you have cleaned the battery, dry the battery with compressed air or damp
antistatic cleaning cloth (cotton, for example). You can also use other applicable
methods to dry the battery.
 If there is liquid in the battery tray, remove it by suction and obey an approved
procedure to discard it. For details, see EN 62485-3 and the ZVEI information
leaflet Safety measures for the handling of electrolyte for lead-acid batteries.
 You can also clean a vehicle traction battery with high pressure cleaning
equipment. See the instructions of the high pressure cleaning equipment.
Instructions for how to avoid damage to the plastic parts of batteries:
 Make sure that you do not cause damage to the plastic parts of batteries, such as
lids, the insulation of the intercell connectors and other connectors.
 Before you clean the battery, tighten the intercell connectors down or push them in
tightly.
 Make sure that the connectors are in their correct position and closed.
 Do not use cleaning agents.
 The maximum permitted temperature setting for the high pressure cleaning
equipment is 140 ºC.
Thus, you can make sure that 30 cm behind the jet nozzle, the temperature is no
more than 60 ºC.
 Make sure that the distance between the jet nozzle of the high pressure cleaning
equipment and the battery is no less than 30 cm.
 Make sure that the maximum working pressure is no more than 50 bar.
 Clean large surface areas of the battery at a time to avoid heating the battery too
much.
 Do not leave the jet on one spot for a longer period of time than 3 seconds.
 After you have cleaned the battery, dry the battery with compressed air or damp
antistatic cleaning cloth (cotton, for example). You can also use other applicable
methods to dry the battery.
 Do not use air heaters with an open flame or with glow wires.
 Make sure that the surface temperature of the battery is no more than 60 ºC.
 If there is liquid in the battery tray, remove it by suction and obey an approved
procedure to discard it. For details, see EN 62485-3 and the ZVEI information
leaflet Safety measures for the handling of electrolyte for lead-acid batteries.
7.3 Requirements for battery charging areas
The battery charging areas must be in compliance with the standard EN 62485-3.
 The battery charging area must be clearly defined by marking it permanently on the
floor. The floor coating must be acid resistant and have a resistance to ground less
than 100 MΩ to avoid sparks by electrostatic discharge.
 The battery charging area must be adequately spaced from materials that can
constitute a hazard, such as inflammable or explosive goods.
 Except during essential maintenance or repair, the battery charging area must not
be subjected to any sources of ignition, such as sparks or sources of high
temperature. The exception is where high temperature equipment is required for
work on the battery and this must be in the control of trained and authorized
personnel who take all necessary precautions.
 It is important to prevent electrostatic discharges when working with batteries. Make

sure that you do not wear clothes and footwear that can build up electrostatic
discharge. Absorbent cloth for battery cleaning must be antistatic and used
moistened only with water without any cleaning agents.
 When the battery is being charged or serviced, there must be a space 0.8 m wide
on the sides of the truck that require access.
 When charging batteries on or off the truck, the ventilation requirements of
EN 62485-3 clause 6 must be met.
 The charger and other devices in the battery charging area, for example the battery
changing equipment, must be installed so that they do not get damaged if the truck
moves.
 The battery charging area must not be vulnerable to falling objects, drip water or
liquids that can leak from damaged pipes.
 If you use battery replacement equipment, make sure that it is suitable for the
battery trays and weights. Examine the battery replacement equipment regularly for
damage. Battery replacement must be done by personnel trained to handle heavy
weights. It is recommended that the batteries are replaced laterally with certified
supporting devices to minimize the risk of batteries tipping over, crushing or
damaging other equipment, etc.
 The battery charging area must contain appropriate warning signs:
- Follow the instructions
- Battery hazard
- Dangerous voltage
- Highly corrosive electrolyte
- Use protective clothes and goggles
- Prohibition of naked flame
- Explosion hazard.
 The battery charging area must contain fire extinguishing equipment.
 The disassembly and disposal of batteries must be done according to the prevailing
local regulation and by qualified personnel only.
7.4 Charge the battery
Figure 159. Connectors overview
1. Charger connector 3. Battery connector

2. Truck connector
CAUTION
Make sure that the charger is the appropriate model (correct battery type and voltage)
and that the battery has sufficient ventilation.
1. Park the truck in a reserved battery charging area.
2. Switch the power of the truck off.

3. Make sure that the charger has
been switched off.
4. Open the battery door, see section 5.6.4.
5. Disconnect the battery connector

from the truck connector.
6. Connect the battery connector to the

charger connector.
7. Switch the charger on.
After charging
1. Switch the charger off.
2. Disconnect the battery connector

from the charger connector. Hold the
connectors; do not pull the cables.
3. Check the battery according to the battery maintenance instructions of the

manufacturer.
4. Connect the battery connector to the

truck connector. Make sure that the
battery cables remain completely
safe within the frame of the truck.
5. Close the battery door.
WARNING
Do not leave the battery cables outside of the truck. The cables can get damaged and
cause a serious burning hazard!
7.5 Measure the specific gravity of the battery
Measure the specific gravity of the battery fluid according to the instructions of the
manufacturer. The acid density of a fully charged battery is 1.28 to 1.30 at +30°C. The
gravity is:
 1.24 when the battery is 3/4 charged.

 1.15 when the battery is empty. Charge the battery immediately.
7.6 Replace the battery
CAUTION
Always follow the instructions of the manufacturer when you replace the battery.
When you replace the battery, use a battery with equivalent dimensions and weight to
maintain the stability and the braking properties of the truck. The minimum weight of
the battery is indicated on the identification plate of the truck.
When you install a battery, use the applicable tools to move, connect and attach the
battery correctly. Do not keep tools or other metal objects on top of uncovered
batteries.
Make sure that the capacity of the used lifting device is sufficient. When you use a
lifting device to lift the battery, put a non-conductive plate on top of the battery to
prevent the risk of a short circuit. This is not necessary, if the lifting device has
sufficient insulation and is equipped with a distributor, or if the pole shoes and cell
combinations are fully protected.
There are 2 alternative ways for battery replacement: the standard battery replacement
and the battery sideway exchange. For more information of the battery sideway
exchange, see section 15.15.
7.6.1 Replace the battery with the standard equipment
Figure 160. Standard battery replacement overview
1. Battery connector 3. Battery

2. Latch
To replace the battery with the standard equipment:
NOTE: If you have a truck with a cabin, you must open the roof cover (see section
5.20.1) and the rear window (see section 5.20), before you replace the battery.
1. Open the battery door, see section 5.6.4.

2. Open the battery cover, see section 5.6.5.
3. Disconnect the battery connector.
4. Push the latch forwards along the

axis.
NOTE: Do not turn the handle.
5. Attach 4 lifting hooks (size 6) to the

battery. Note the correct lifting chain
lengths.
NOTE: Make sure that you use
applicable lifting devices and follow
the safety instructions given by the
lifting device manufacturer.
6. Remove the battery.
7. Insert a new battery to the truck.

8. Connect the battery connector.
9. Guide the battery cable, see section 7.6.2.
10. To close the latch, turn the handle.
11. Close the battery door.

12. Close the battery cover.
7.6.2 Guide the battery cable
You must guide the battery cable so that it does not get stuck between lock of the
battery door.
Guide the battery cable on the side of the battery and through the cable guide, see
Figure 161.
Figure 161. Guide the battery cable
7.6.3 Battery sideway exchange
If you have a truck with the battery sideway exchange, you must have the battery tray or
the roller bed to replace the battery, see Figure 162. You can also use the battery
sideway exchange tools to replace the battery, see section 15.15.
Figure 162. Battery tray and battery roller bed
1. Battery roller bed 2. Battery tray

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EP25-35(C)N Service Manual

Batteries marked with this sign must be recycled.

7.1 Safety regulations concerning the handling of lead-acid

Use protective glasses and clothes when working on batteries.

Risk of explosion and fire, avoid short circuits!

Electrolyte is highly corrosive.

Batteries and cells are heavy.

Dangerous electrical voltage!

Pay attention to the hazards that can be caused by batteries.

7.2 Battery maintenance

7.2.1 Daily maintenance

Charge the battery after every discharge.

7.2.2 Weekly maintenance

7.2.3 Monthly maintenance

Before you talk to the battery manufacturer, measure and record:

7.2.4 Annual maintenance

7.2.5 General maintenance

 The battery is fully charged.

 Do the equalizing charge monthly.

7.2.8 How to clean batteries

It is important that you keep the battery clean. A clean battery:

 Can prevent accidents.

General instructions for battery maintenance:

 Use protective eyewear and protective clothing.

Instructions for how to clean vehicle traction batteries:

Instructions for how to avoid damage to the plastic parts of batteries:

7.3 Requirements for battery charging areas

 It is important to prevent electrostatic discharges when working with batteries. Make

7.4 Charge the battery

Figure 159. Connectors overview

1. Charger connector 3. Battery connector

1. Park the truck in a reserved battery charging area.

2. Switch the power of the truck off.

4. Open the battery door, see section 5.6.4.

5. Disconnect the battery connector

6. Connect the battery connector to the

7. Switch the charger on.

1. Switch the charger off.

2. Disconnect the battery connector

3. Check the battery according to the battery maintenance instructions of the

4. Connect the battery connector to the

5. Close the battery door.

7.5 Measure the specific gravity of the battery

 1.24 when the battery is 3/4 charged.

7.6 Replace the battery

7.6.1 Replace the battery with the standard equipment

Figure 160. Standard battery replacement overview

1. Battery connector 3. Battery

To replace the battery with the standard equipment:

1. Open the battery door, see section 5.6.4.

3. Disconnect the battery connector.

4. Push the latch forwards along the

5. Attach 4 lifting hooks (size 6) to the

6. Remove the battery.

7. Insert a new battery to the truck.

10. To close the latch, turn the handle.

11. Close the battery door.

7.6.2 Guide the battery cable

Figure 161. Guide the battery cable