How To Make Your Forklift Battery Last Longer?

By Author: Canadian Forklift Safety Group
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Every aspect of forklift training is important and an important practice is how to take care of your forklift battery and make it last longer. A discharged battery in the middle of the job that needs immediate replacement can cause loss of work hours and more such frequent episodes leads to undue and unplanned expenditure as well. As forklift operators, we have to therefore take utmost care that our forklift batteries are properly maintained and should last longer as expected.
Why Forklift Battery maintenance is important?
Right knowledge of battery maintenance will help in the long run to:
• Reduce workplace and battery replacement costs
• It is important for workplace safety that all forklift operators should be proficient in battery maintenance procedures.
• To increase forklift life as most forklifts are battery powered. And their batteries are particularly expensive. So if forklift battery is not maintained properly, it will shorten the life span of battery. Besides, it can also interfere with proper working of a forklift.
Let's discuss some of the key elements of proper maintenance ...
... of a forklift battery:
Battery re-charging/charging procedure
How a forklift battery is charged/recharged acts a determining factor in its long run. If the batteries are not charged properly, it disrupts their normal charging cycle and can lead to faster discharging and ultimately a replacement might be the only way out.
Right charging procedure:
• Cell voltages of battery should be even and therefore after every 5 to 10 charge cycles, equalize/weekend charge option should be selected.
• Avoid charging after completely discharging your forklift battery. When the mark hits 30%, you know it's time for battery recharge.
• Battery charging should always be done in a well ventilated area for worker safety.
Things to Avoid
• You should avoid over-discharging your battery. If it's recharged from near complete discharged state, life span of battery decreases.
• Avoid hard sulphation of battery by letting sit idle while completely discharged. It'll ruin your battery beyond repair.
• Don't charge in small bouts, also called opportunity charging. Charge completely from the 20-30% mark.
• Don't take your forklift out for a spin without fully charging the battery.
Battery's Fluid Levels
Battery maintenance is not just limited to taking care of charging discharging cycles. One must know what lies in there. Optimum water levels should be maintained properly to increase the life span of battery. The way it's done is:
• Water levels should be checked after every 10 charge cycles for initial couple of years. In case of a reconditioned battery, do this every 5 charges. Check water levels and top up appropriately every 10 or so charges for the first few years.
• If your battery is fitted with a Single Point Watering kit, top them up at the end of every charge, not before that.
• Make sure you are using only distilled water for topping up at the end of charge.
• Check water level in a couple of pilot cells every 5 charges to see if the water level is above perforated plastic element protector.
• Over-filling should be avoided as it causes overflow and acid loss during the next charge which leads to significant loss of battery life.
This just an overview of the procedures to follow to guarantee a long battery span. For complete training, a formal Forklift training and certification from an authorized organization, such as Mississauga's Canadian Forklift Safety Group, is needed.