Battery Replacement Process for Skyjack 4632

Overview of Battery Replacement

00:00

• The existing setup includes four 6-volt lead-acid batteries, totaling 240 volts. The replacement will involve installing lithium iron phosphate (LiFePO4) batteries rated at 25.6V and 13Ah.

00:00

• Client concerns included short usage time and inconvenience related to distilled water replenishment, prompting the inquiry about a possible battery upgrade. After providing a suitable quote, the client agreed to proceed with the replacement.

Testing Procedures Before Installation

01:11

• Initial tests were conducted to check if charging was functioning correctly; it was confirmed that the current charge level was at 100%. A discharge test was planned to ensure proper functionality before proceeding with installation.

02:29

• During testing, it was noted that while discharging, the battery showed a usage of approximately 4.9A, indicating active consumption during this phase. The charge dropped to 97% after some use.

Installation Steps

02:29

• Following successful discharge testing, recharging commenced with an observed temperature increase to 7°C as charging progressed back up to full capacity (100%). This indicates effective thermal management during operation.

04:10

• Careful attention was given to cable orientation during installation; ensuring connections were secure and avoiding potential interference or damage from misaligned cables is crucial for safety and performance.

Final Checks Post Installation

05:25

• Once all connections were made, including linking power on/off switches properly, final checks confirmed no issues with power supply or communication systems between components were detected post-installation. All systems appeared operationally sound at this stage of completion.

Overview of the Skyjack 4632 Aerial Work Platform

The Skyjack 4632 is a versatile and robust aerial work platform designed for various applications, particularly in construction and maintenance. With a working height ranging from 32 to 38 feet, this scissor lift can accommodate up to 900 pounds, making it ideal for transporting personnel, tools, and materials efficiently. Its compact design, with a width of 46 inches, allows it to navigate tight spaces while providing a stable platform for operators.

Key Features of the Skyjack 4632

• Driveable at Full Height: Operators can maneuver the lift while elevated, enhancing productivity.
• Variable Rear Wheel Hydraulic Drive: Offers smooth operation and control.
• Dual Parking Brakes: Ensures safety during operation.
• Proportional Controls: Allows precise movements of the lift and drive functions.
• Low Voltage Battery Protection: Prevents battery damage from over-discharge.

Transitioning from Lead-Acid to Lithium Iron Phosphate Batteries

Existing Battery Setup

The original configuration of the Skyjack 4632 includes four 6-volt lead-acid batteries, totaling 240 volts. While lead-acid batteries have been a reliable power source, they come with significant drawbacks such as short usage times and the inconvenience of regular maintenance, including distilled water replenishment.

Benefits of Upgrading to Lithium Iron Phosphate (LiFePO4) Batteries

The decision to replace lead-acid batteries with SPIDERWAY’s LiFePO4 batteries rated at 25.6V and 13Ah brings numerous advantages:

• Longer Lifespan: SPIDERWAY LiFePO4 batteries offer over 6000 cycles, significantly outlasting traditional lead-acid batteries, which typically last around 500-1000 cycles.
• Faster Charging: LiFePO4 batteries can be charged much quicker than lead-acid counterparts. This rapid charging capability minimizes downtime, allowing for more efficient operations.
• Reduced Weight: These lithium batteries are lighter—often weighing 50-70% less than lead-acid batteries—improving the overall efficiency and handling of the aerial work platform.
• Maintenance-Free Operation: Unlike lead-acid batteries that require regular maintenance, LiFePO4 batteries are virtually maintenance-free, eliminating the need for distilled water replenishment and reducing operational hassles.
• Enhanced Safety Features: SPIDERWAY’s LiFePO4 batteries utilize non-flammable electrolytes and possess robust thermal stability, significantly lowering the risk of fire or thermal runaway compared to traditional battery technologies.

Installation Process

The installation process for the new lithium batteries involved several critical steps:

1. Initial Testing: The existing battery system was tested to confirm charging functionality, with an initial charge level confirmed at 100%.
2. Discharge Testing: A discharge test was conducted to assess battery performance under load conditions, revealing an active consumption of approximately 4.9 amps during testing.
3. Preparation for Installation: Ensuring proper connections and compatibility with existing systems was paramount. The team paid special attention to cable orientation to avoid potential issues.
4. Final Checks: After installation, power functionality was thoroughly tested, confirming that all systems operated normally without any apparent issues.

Upgrading the Skyjack 4632 aerial work platform from lead-acid to SPIDERWAY lithium iron phosphate (LiFePO4) batteries represents a significant enhancement in performance, safety, and efficiency. With longer lifespans, faster charging times, reduced weight, and minimal maintenance requirements, these batteries not only improve operational capabilities but also contribute to a more sustainable approach in industrial applications.

For those seeking reliable power solutions for aerial work platforms or other industrial vehicles, SPIDERWAY stands out as a trusted manufacturer committed to quality and innovation in lithium battery technology. By choosing SPIDERWAY’s LiFePO4 batteries, businesses can optimize their operations while ensuring safety and reliability in their equipment.