Industrial forklift batteries are designed around a single shift use. A forklift battery being used only one shift has a life expectancy on average of five years. With proper care and maintenance, the battery life can be extended up to ten years or more. Follow the guidelines in this article and get your monies worth out of your industrial batteries.
Discharging Your Industrial Battery
Recharge the battery when it is discharged to 20-30%
Typically, forklifts are set to show 0% on the battery discharge indicator (BDI) when the battery still has 20% capacity. Ask your forklift technician to verify those settings. If they can’t verify this, give me a call at 513-274-7497 if you are in the Cincinnati area. I have software for several brands and may be able to help.
Discharging a battery below 20% can have negative effects on both the battery and the forklift. Running a forklift on a dead battery can cause the electrical components to overheat and cause expensive damage.
Always Allow Your Battery to Charge Completely
There are roughly 1,500 charge cycles expected during an industrial battery’s life expectancy. If you only charge a battery halfway, that is still counted as a charge cycle. The same as if it were charged fully.
Avoid Extreme Temperatures
Battery life can be practically cut in half once the ambient temperature reaches 92 degrees. On the other hand, battery performance drops 30 percent when the temperature reaches 30 degrees. If your forklift operates in extreme temperatures, use a battery designed for those conditions.
Don’t Charge Batteries Mid-Shift
As explained above, every charge is counted as a charge cycle. the ideal time to charge your forklift battery is at 20-30%. Charging a battery with 50% or more left in its charge is like throwing away half a charge cycle. You’ve already counted a charging cycle, so use the whole thing.
Do Not Charge a Battery During Lunch Breaks (Opportunity Charge)
Opportunity charging or quick charging shortens a battery’s lifespan. Think of it like this: a battery is “born” with approximately 1,500 charges in it. The more often it gets charged, the quicker it gets used up.
– Charge once a day and the battery should last five years.
– Charge twice a day and you can cut that lifespan in half.
To get the most out of your forklift battery: always charge your forklift battery completely, and never interrupt a charging cycle.
Forklift Battery Maintenance
Maintaining a forklift battery can be easy: check the water once a week and clean the top once a month. Most battery companies will set you up on a schedule for every six months to get your battery some periodic maintenance. By this time, there could be excessive buildup on the battery and many cell voltage issues that aren’t caught. If your battery looks like the one below, you’re getting forked. Call us today and get you battery maintenance under control. Proper maintenance is crucial for safety and to extend the life of your battery.
Here are some simple Do’s and Don’ts:
Wear Protective Gear
Batteries contain sulfuric acid, a chemical that can cause severe burns. Follow OSHA recommendations for protective gear and remove all metallic jewelry when handling and charging industrial batteries.
Check the Battery’s Water Level
Add deionized or distilled water every five to ten charges (check manufacturer recommendations). Add water after charging – never before, and if you notice white crystals on the lead plates, call in a battery technician immediately.
Clean Batteries Every Month
Using battery cleaner or warm water, clean the top of each battery monthly. This is another example of easy, but often neglected maintenance. Chemical build-up can lead to case corrosion and may void the manufacturer’s warranty. Trust me, they will look for any excuse to void the warranty.
Do Not Attempt to Pick Up a Forklift Battery
Forklift batteries can weigh up to 3,000 lbs. No single person or team of people should attempt to lift a forklift battery. Use equipment such as a pallet jack equipped with a transfer station. The battery weight can be found stamped on the side of the battery case.
Do Not Use a Battery That Emits Smoke
If a battery begins smoking, disconnect it from the charger or truck immediately. Do not use this battery again. Severe damage or injury can occur. Call a service technician right away. 513-274-7497
Though electric forklifts cost more versus gas/ICE forklifts in the beginning, they have a lower cost of ownership in the long run. To ensure your company gets the maximum value from their electric lift truck, follow the proper battery maintenance and charging.