TM 10-6140-200-14
Table 3-1. Storage battery troubleshooting chart
Possible Remedy
Possible Cause
Symptoms
1. Replace or repair defective charger
1. Malfunctioning Charging Equipment
Battery overheats during
parts (timer, voltage sensitive relay,
charge
control board, etc.)
2. Adjust start and/or finish charging
2. Charging equipment out of adjustment.
rates.
3. Replace or repair problem cell(s).
3. Defective or weak cell(s).
4. Replace battery.
4. Battery worn out and beyond
economical repair.
5. Check for hot wires, cells, intercell
5. High resistance connection within
connectors, charging plugs, etc.
battery.
Repair or replace defective
component.
6. Water battery to proper level at end
6. Low electrolyte level.
of charge.
7. Open the compartment during charge
7. Battery charged in the vehicle with
or charge the battery out of the truck
battery compartment closed or the
with the tray cover opened.
tray cover closed.
8. Allow battery to cool below 90
8. Battery over 110 degrees F. when
degrees F. before charging. Use cool-
placed on charge.
ing fans to speed process.
1. See remedies 3 through 8 above.
1. See causes 3 through 8 above.
Battery overheats during
discharge
2. Repair or replace defective lift truck
2. Worn out bearings, brakes dragging or
parts.
other vehicle problem causing high
current draws.
3. a. Requires drivers to return battery
3. Overdischarge of battery.
for recharge when vehicle begins
to slow down.
b. Put more batteries into service.
1. See that battery has reached full charge
1. Battery not fully charged before placed
Battery not completing
specific gravity before placing into
into operation.
full work shift.
operation.
2. Repair or replace cell(s) or battery.
2. Weak, leaking or defective cell(s) in
battery
3. Remove grounds or shorts.
3. Grounds or shorts in the battery.
4. Replace battery with equal or higher
4. Battery worn out and beyond
capacity battery.
economical repair.
5. a. Replace battery with one having
5. Battery too small for job.
higher capacity.
b. Purchase extra batteries (with
higher capacity if possible) and
change them more frequently.
6. Troubleshoot vehicle and repair.
6. Electrical or mechanical problem in
vehicle.
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