A typical forklift truck battery is 30% of the value of a new forklift truck and will run for approximately 6000 hours. It will be your fuel for the next five years or more, provided you follow the manufacturer’s instructions for maintenance.
In our list of tips and practices we offer useful suggestions that will help you avoid common mistakes and keep your battery (and your truck) in optimal condition.
– Battery charging
Full discharge causes damage to the battery and causes the electrical components of the truck to stop working. This causes major damage to the truck, engine failure and component burnout.
If that’s not enough, the truck is no longer operating optimally. When the battery is 80% discharged, the truck’s traction and hydraulics slow down, indicating that it is time to charge it. If the battery is discharged, you will need to fully charge it for an uninterrupted period of 8 hours and never disconnect the battery from the charger before the process is complete.
– Check the water level periodically and always maintain the level after loading.
Water is critical to the operation (and life) of the battery. During the charge cycle, water is heated and dissociates into two gases, releasing hydrogen bubbles on the negative plates and oxygen on the positive plates. The plates are exposed to air when the water level in a battery drops too low. This causes the active material in the plates to dry out and become brittle, causing permanent damage.
For this reason, it is essential to add distilled water to the battery periodically (usually every 5 to 10 charges). Be careful not to add too much water. If the water level exceeds the mark, it will spill out… causing permanent damage.
Add the water after charging the battery, not before.
– Be attentive to maintenance.
Be attentive to sulfation which deteriorates the connections the connections, screws and connectors of your battery, in such a case it is necessary to replace these components for the battery to work properly. Ask us for the necessary replacement to put the battery in optimal condition.
Clean the sulfated battery terminals and protect the connection terminals with antirust grease to prevent sulfation.
– Let the battery rest during lunch.
It is often tempting to quickly charge the battery during short breaks. This is known in the industry as “occasional charging “. Battery life depends on charge cycles (i.e., the number of times it is charged). Short charge cycles slowly reduce the battery’s efficiency until it reaches a point where it stops charging. Instead of charging the battery, let the truck cool down during stops.
– Beware of fast charging cycles.
Fast charge cycles can shorten downtime by 10%, but they come at a price. Although all battery systems can be fast-charged, the heat generated during the process can drastically reduce the life of lead-acid batteries. The same is true for lithium-nickel batteries, but to a lesser extent. Any knowledgeable distributor or battery supplier can advise you on how to avoid temperature control problems while increasing productivity.
RESERVE fast charge cycles for emergency situations.
– Protect your charger.
The battery charger is a major investment and should be stored in a safe place to prevent it from deteriorating. The Battery chargers should be be kept away from moving forklifts and plant equipment. Make sure that cables and plugs do not touch the ground so that they are not crushed under the wheels.
Actions to be taken:
- Do not charge the battery when it is slightly discharged or you will kill it before its time.
- Before disconnecting the battery from the charger, make sure that the charging cycle has been completed.
- Add distilled water only.
- Replace damaged or sulfated screws and flexible bridges
- Check the condition of the plug and battery connector periodically.
- Electric batteries produce a gas mixture that is explosive at a concentration of only 4%.
- Battery charging areas are hazardous, given the ventilation, ignition, electrical and environmental hazards involved.
