Enersys – Forklift Battery Maintenance Explained
Forklift Battery and Charger Preventive Maintenance programs – “A Wise Investment”
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Photos: (from left to right): A) Knowing the condition of your lift truck batteries is key to long and productive battery life. B) Checking specific gravity and voltages regularly helps detect possible issues early. C) Battery washing will help extend battery life. D) Poor battery maintenance can cause loss of production, minimize return on investment and can even cause possible occupational safety risks.
It is no secret that electric lift trucks are a very costly investment. Unfortunately, that cost skyrockets when those lift trucks are out-of-service. Out-of-service lift trucks don’t move product; and companies don’t get paid when that product doesn’t move. All too often, electric lift trucks are out-of-service due to a bad battery.
As users of, and service providers for, electric lift trucks and related equipment, we have all experienced issues related to poor battery performance. Batteries never seem to provide the runtime we expect and, all-too-often, they leak and smell. Can’t anybody manufacture a battery that works the way we expect it to???
While there are variances in the quality of batteries (usually proportional to the price), the main reason that batteries fail to deliver is because they are not inspected and maintained properly. Proper battery and charger maintenance is the key to getting the runtime and longevity that matches or exceeds the investment made.
Sales professionals usually do a good job of “spec’ing” and selling materials handling equipment, but seldom focus the same attention on promoting service and maintenance packages to support that materials handling equipment. Why is that? The answer is simple. Many sales professionals receive little or no compensation for selling service and maintenance packages.
Electric lift truck users are also guilty of not accepting the importance of proper maintenance, especially when it comes to their batteries and chargers. Users are far more understanding of the need to maintain their lift trucks regularly, but fail to understand the need for regular battery and charger maintenance. Most users think that they just need to water their batteries “occasionally” and plug up the battery to the charger when it goes “dead”. This could not be further from the truth. Most users understand the importance of partnering with a reputable lift truck service provider to maintain their lift trucks. It is equally as critical that they partner with a reputable battery / charger service provider, as well. Qualified battery / charger service providers are experts in the care, maintenance, and repair of batteries and chargers.
Reputable battery / charger service providers usually offer comprehensive preventive maintenance programs to help users get the most out of their battery / charger investments. These programs can be specifically tailored to meet the specific needs of the user. The following is a list of basic battery / charger maintenance recommendations:
Lift Truck Batteries (Weekly / Bi-weekly)
- Check cell water levels, add water as needed
- Wipe down top of battery with neutralizer as needed
- Inspect for physical damage (cables, connectors, contact tips, cell tops, inter-cell connectors watering systems, excessive corrosion, signs of excessive heat)
Forklift Batteries (Quarterly)
- Record cell voltage readings of each cell
- Record specific gravity readings of high / low cells
- Evaluate readings to determine if cell balancing / acid adjustment is needed
- Inspect for physical damage (cables, connectors, contact tips, cell tops, inter-cell connectors, excessive corrosion, signs of excessive heat)
- If equipped, inspect watering systems for physical damage and proper operation
- Wipe down top of batteries with neutralizer
- Review findings / recommendations with customer
- Make necessary repairs
Lift Truck Batteries (Semi-annually / Annually)
- Batteries should be pressure-washed to remove acid, corrosion, and other contaminates not removed by regular wipe-down
- Chargers (Semi-annually)
- Verify that chargers are correctly matched (AH rating) to batteries to avoid damage from over / under charging
- Verify charger output is consistent with its nameplate rating
- Check AC and DC cables, plugs, contact tips, and connectors for damage, exposed copper, and signs of excessive heat
- Verify function and accuracy of ammeter
- Review findings / recommendations with customer
- Make necessary adjustments / repairs
Forklift Fast Chargers (Quarterly)
- Check AC and DC cables, plugs, contact tips, and connectors for damage, exposed copper, and signs of excessive heat
- Verify proper programming to include AH rating and equalize schedule
- Download data management / exception reports
- Review findings / recommendations with customer
- Make necessary adjustments / repairs
The above list is generic. Every application is different and requires a battery / charger maintenance program specifically designed to meet the requirements of the user. Some users prefer to water their batteries while others want watering included in their maintenance programs.
Rely on your battery / charger service provider to make the right recommendations for your specific application. With proper maintenance, your batteries will not only smell good, but they will give you the consistent, long-term performance that meets or exceeds your expectations and your investment.
For more information, contact your local EnerSys Product Support Representative at 1-800-EnerSys