Electric Forklift Battery Maintenance Guide
An electric forklift is a critical piece of equipment in a warehouse or logistics operation. Without one, you can’t get important work done day in and day out. It’s vital to keep your unit up and running, which starts with understanding electric forklift battery maintenance. Read this guide to learn how to care for your battery.
The Importance of Electric Forklift Battery Maintenance
Routine maintenance and cleaning of equipment can feel like a burden when you already have a busy work environment. Because of this, some companies fail to make it a priority, focusing on other aspects of the business, such as productivity. However, it’s hard to be productive if your forklift breaks down. Even if you have a fleet, losing one forklift has an impact on how much work gets done each day and how your warehouse runs.
Safety Hazards
One of the most critical reasons to put more effort into battery maintenance is safety. Discussion about forklift safety often centers around proper operation, safe working conditions and following weight limits for the forks. It’s easy to overlook the potential threats hiding inside the mechanics of the unit.
An electric forklift battery can be dangerous if it is not properly maintained. One potential hazard is the risk of explosion or fire. If the battery is overcharged, it can potentially leak or even explode, which can be dangerous for both the operator and those working in the area.
In addition to the risk of explosion, batteries that are not properly taken care of can pose a safety risk due to decreased performance. If the battery is not charged enough, the forklift may lose power while in use, which could lead to accidents or equipment failure.
Larger Repairs
Failing to maintain a forklift battery could also result in you spending more money in other ways. For instance, problems with your battery can affect the wiring and electrical systems of the forklift. Rather than just paying the cost of the tools needed for forklift battery maintenance or the price of a new battery, you may also need to find the funds to cover electrical repairs or even replace the entire forklift.
Any failures of the forklift could also cause damage to other items. Imagine if a forklift battery fails while an operator is carrying a load in a tight space. The load may fall to the ground, resulting in broken inventory that your company could have to pay for. The forklift could also hit something in the warehouse, such as a shelving unit or other important equipment. Repairing these items can take a chunk out of your bottom line.
Forklift Lifespan
In general, the expected lifespan of an electric forklift battery ranges from three to five years, but maintenance habits can impact your results. Batteries that are consistently undercharged or overcharged can suffer from decreased performance and may need to be replaced more frequently.
Additionally, the operating conditions that the battery is subjected to can impact its lifespan. For example, batteries that are used in extreme temperatures or subjected to frequent vibration may have a shorter lifespan than those used in more moderate conditions.
Overall, learning the right ways to maintain a battery and committing to staying on top of cleaning and repairs can keep your team safer and more productive and prevent unexpected costs.
Key Steps in Electric Forklift Battery Maintenance
Taking care of a forklift battery doesn’t have to be overly complicated, but it does require thought and effort. With a few steps, it can become much easier to keep your batteries and forklifts in good working order.
Making a Schedule
One of the first things you can do is create a maintenance schedule for your forklifts. By planning out dates for different tasks to be completed on each forklift, you can make sure each battery is always performing as it should and get ahead of any problems before they escalate.
To create a schedule, start by looking at the manufacturer’s guide for the forklift. Often, the manual that comes with the forklift will include recommended intervals for certain services. When it comes to batteries, look for any suggested cleanings that should be completed after a certain amount of charge cycles.
You should also base your schedule on any previous maintenance or repairs. If you have purchased a new forklift, this is easy because you are the first one to build the repair history. For a used model, do your best to get maintenance details and records when you make your purchase. You want information such as the age of the unit, the age of the battery, the manufacturer of the battery, the number of charge cycles that have happened and any repairs made to the unit.
If you can’t get this information, it’s a good idea to have a mechanic assess the battery to make sure it is in good working order, then do a cleaning and an inspection as the base of your new maintenance schedule.
Checking Electrolyte Levels
The electrolyte levels in a forklift battery are a major part of forklift battery maintenance. Most batteries have a liquid electrolyte solution in the individual cells. The electrolyte solution is composed of water and sulfuric acid, and it helps to conduct electricity within the battery. Maintaining the correct electrolyte levels is crucial to the proper functioning of the battery.
To check the electrolyte levels in an electric forklift battery, you will need to remove the cell caps and visually inspect the level of the electrolyte solution in each cell. It is important to keep the electrolyte levels at the proper level to ensure the battery operates correctly. If the levels are too low, the battery may not be able to hold a charge and may suffer from decreased performance. On the other hand, if the levels are too high, the battery may be at risk of leaking or even exploding.
To maintain the correct electrolyte levels, you will need to periodically check the levels and top them up as needed. This can typically be done by adding distilled water to the cells. Be sure to use only distilled water, as tap water can contain impurities that can interfere with the performance of the battery.
Cleaning the Battery
Cleaning an electric forklift battery involves removing any dirt or debris that may have accumulated on the surface of the battery. This is an important part of maintaining the battery and ensuring that it operates efficiently. Here are the steps involved in cleaning an electric forklift battery:
Gather the necessary materials. You will need a solution of water and baking soda, as well as protective gear such as gloves and goggles.
Prepare the cleaning solution. Use the baking soda and water to create a slightly abrasive paste. The paste should be thick enough to stick to the surface of the battery but not so thick that it is difficult to spread.
Apply the cleaning solution to the battery. Use a soft cloth or brush to gently scrub the surface of the battery, taking care not to damage the cells. Be sure to pay particular attention to any areas that may have accumulated dirt or debris.
Rinse the battery. Once you have finished scrubbing the battery, use a clean cloth and a little water to rinse away the cleaning solution. Be sure to remove all of the solution to prevent it from drying on the surface of the battery.
Dry the battery. Use a clean cloth to carefully dry the surface of the unit. Be sure to remove any excess water to prevent it from dripping into the cells.
This light cleaning routine should be a weekly aspect of your forklift battery maintenance to prevent buildup from accumulating. It’s a good idea to create a log or checklist so your staff can write down when they’ve cleaned a particular unit for accurate record-keeping and scheduling.
Inspecting Battery Components
Your maintenance plan should also have a schedule for inspections. Regularly checking the status of the different battery components helps you identify problems ahead of time and plan out repairs rather than just reacting to sudden failures.
Resources
Exponential Power can service all makes and models. Some benefits of battery repair are:
- extended battery life
- prevention of damage to trucks
- reduced motor and contact replacement
- increased productivity
- improved running hours
- improved safety
Field service
In many cases, we can fix your battery or charger right in your plant, so you don’t have the inconvenience of extended downtime.
Exponential Power mobile service trucks are equipped to provide immediate field service. Our service technicians can also provide in-plant battery and charger surveys, OSHA regulation information and maintenance training.
Our service technicians are not only highly skilled and seasoned trouble-shooters, they are also advisers, educators and consultants.
Rental Batteries and Chargers
Exponential Power has a large fleet of rental batteries and chargers for short term or long term needs.
Pick-up and Delivery Service
Exponential Power personnel will assist in assuring that the battery removal and installation is done safely.
24/7 Emergency Service
Exponential Power offers 24/7 service for Exponential Power-supplied battery changing systems.
Contact Exponential Power for a battery service quote.
Typical Work Performed During Reconditioning
- Steam clean / remove corrosion
- Equalize charge
- Adjust specific gravity
- Six hour discharge test
- Replace or repair defective cells
- Repair cover to jar leaks
- Remove sulphation (desulfation)
- Replace broken jars or covers
- Replace cables and connectors
- Clean and paint
Remember, reconditioning during early detection can often double useful life, but if you delay you may totally destroy the battery and damage your truck’s drive motor as well as other electrical components. Don’t delay. all Exponential Power repairs are fully warranted.
Battery Cleaning / Wash Service
We offer on-site battery cleaning and battery washing services, which will help lengthen service life and eliminate environmental concerns. We also sell battery washing equipment.
What happens if you don’t clean batteries?
- Battery life can be reduced
- Corrosion can cause battery cells to rupture and leak
- Metal cases can corrode away
- Electrolytes can damage operator’s clothes and irritate the skin
- Voltage leaks to ground can create nuisance electrical faults
- Lifting ears can weaken causing potential safety issues
How often should a battery be cleaned?
This depends mainly on how well the batteries are watered. In many instances an annual wash is adequate. However, if over-watering occurs regularly and/or it is a dusty or dirty environment, more frequent washing may be required.
To request a quote on battery washing or battery washing equipment, click here.
- Batteries: Forklift, Stationary, UPS
- Battery Handling Equipment
- Battery Chargers
- Battery Racks
- Battery Cabinets / Enclosures
- Battery Test Equipment
- Battery Maintenance
- Powered Mobile Carts
- Inverters
- Battery Spill Containment
- Uninterruptible Power Supply Systems
- Used Equipment
Give your battery a lunch break
It’s tempting to fall into the bad habit of quickly charging your truck during breaktimes. In the trade this is known as ‘opportunity charging’. A battery’s lifespan is determined by its charge cycles (i.e. how many charges it’s had). Short charges will result in a steadily declining battery efficiency. to the point where it won’t charge at all. Instead, allow your truck to cool off during downtime.
Water plays a key role in the running (and life expectancy) of your forklift battery. During a charge cycle, it is heated up and splits into two gases, releasing hydrogen bubbles at the negative plates and oxygen at the positive. Allowing the water level in a cell to drop too low exposes plates to the air, allowing the active material in the plates to dry and become brittle, leading to permanent damage.
For this reason, it is essential for distilled water to be added to the battery at regular intervals (usually every 5 to 10 recharges). However don’t be tempted to overfill! Ensure you fill only up to the desired mark or the water will expand and overflow. leading to permanent damage.
Always top up after charging, not before.
Fast charge with caution
Fast charging might reduce downtime by as much as 10%, but it comes at a price. Any battery system can be fast charged, but the heat generated during the process can dramatically reduce a lead-acid battery’s life expectancy. Nickel and lithium batteries suffer from this, but to a much lesser extent. A knowledgable dealer or battery supplier can advise on effective ways to avoid temperature control problems while increasing productivity.
Keep fast charging for emergencies.
Keep a close eye on maintenance
One of the top causes of premature battery failure and loss is sulphation. This occurs naturally. as white sulphuric crystals attach to the lead plates. preventing the battery’s ability to accept, hold and deliver a charge. This problem can be caused by overfilling and is most commonly experienced in warm environments. information about this far-too-frequently occurring problem can be found here
Check your battery for the development of white crystals as part of your daily checks. If you do spot the tell-tale signs of sulphation request a visit from an engineer who can advise on corrective measures.
The Best Practices for Forklift Battery Maintenance
A forklift’s battery life is essential to successfully lift and transport large and heavy materials from one end of an area to another. Without proper care, personnel can expose themselves to possible hazards if they don’t maintain the batteries of forklifts. For example, an employee can get electrocuted if chargers aren’t connected correctly. It’s essential that personnel practice and reiterate every forklift refresher training requirement, especially if they had a recent accident with one. As far as refresher training goes, it’s vital to ensure all employees reiterate and consistently exercise the best practices for forklift battery maintenance so they can improve their skills and avoid future accidents.
Properly Charge the Battery
For many warehouses, there are types of workers that only charge forklift batteries when it’s convenient for them. This is known as “opportunity charging.” Opportunity charging is a poor practice as it can result in the battery overheating if it doesn’t get charged at the correct times. (Avoid quick or opportunity charges unless it’s a Rapid-charge system.) On average, forklifts run on up to two thousand hours a year. They should only run during work hours. A forklift should only be charged at specific temperatures and times and only go through a full battery charge if it falls below thirty percent. So, it’s important not to undercharge or overcharge the battery, as doing so can lessen the lifespan of your forklift.
When charging your forklift battery, it’s important to note that it shouldn’t go above one hundred and thirteen degrees. If that happens, its lifespan will get harmed, it’ll overheat, and some of the water will get boiled away. Additionally, overcharging lithium can cause an explosion. However, when charging the battery, workers must keep the company’s instructions in mind. The battery’s set temperature which shouldn’t be exceeded varies with battery and model type (follow Mfg. recommendations). Ensure battery longevity by following the 8-8-8 rule. During a standard 24hour period, batteries should be in use for eight hours, charged for eight hours, and cooled for eight hours.
Always Exercise Best Forklift Safety Practices
Make sure workers are wearing proper gear when handling forklift batteries. This is part of best forklift safety practices. It’s highly preferred to wear steel-toed work boots, chemical-resistant rubber gloves, an apron, a face shield, and goggles. Loose-fitting clothing must never be worn; some of it could get caught and cause a severe injury or accident. Also, if a worker gets acid on themselves or it gets in their eyes, ensure there’s a washing station nearby so they can thoroughly wash their eyes or other affected areas for at least 15 minutes. If employees are working with lead-based batteries, be aware they can get severely burned by the sulfuric acid contained within batteries if they’re not wearing appropriate clothing.
When practicing and reiterating the best practices for forklift battery maintenance it’s essential to keep repeating the process and ensuring workers receive the necessary training. That way, they’ll remember all the best practices. First Quality Forklift Training provides employers with the suitable material to help get their workers up-to-date on certification information. They also provide the essential skills to succeed as a forklift operator, especially when a worker needs to relearn a skill after experiencing an accident.