Enersys – Forklift Battery Maintenance Explained

Forklift Battery and Charger Preventive Maintenance Programs – “A Wise Investment”

Article Originally By: Scott Weiss & Mark Waycaster

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 even cause potential safety risks.

It is no secret that electric lift trucks are a significant investment. However, the cost can skyrocket when these lift trucks are out of service. Out-of-service lift trucks don’t move products, and companies lose money when products don’t move. Often, electric lift trucks are out of service due to a bad battery.

As users and service providers for electric lift trucks and related equipment, we’ve all experienced issues with poor battery performance. Batteries never seem to provide the runtime we expect, and they often leak or emit odors. Why can’t anyone manufacture a battery that works as expected?

While the quality of batteries can vary (usually in proportion to their price), the main reason batteries fail to deliver is due to a lack of proper inspection and maintenance. Proper battery and charger maintenance is essential for achieving the runtime and longevity that matches or exceeds the initial investment.

Sales professionals do a good job of "spec'ing" and selling materials handling equipment, but often neglect to promote service and maintenance packages to support this equipment. Why? 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 understanding the importance of proper maintenance, particularly for batteries and chargers. Users often realize the need for regular lift truck maintenance but fail to see the necessity of regular battery and charger maintenance. Most users assume they just need to occasionally water their batteries and plug the battery into the charger when it’s dead. This is far from the truth. Users must also partner with reputable battery/charger service providers for regular maintenance, just as they would with lift truck service providers. Qualified service providers specialize in the care, maintenance, and repair of batteries and chargers.

Reputable battery/charger service providers typically offer comprehensive preventive maintenance programs tailored to the user’s needs. Here are some basic battery/charger maintenance recommendations:

Lift Truck Batteries (Weekly / Bi-weekly)

• Check cell water levels, and add water as needed
• Wipe down the top of the battery with a 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 for each cell
• Record specific gravity readings for 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 damage and proper operation
• Wipe down the top of batteries with a neutralizer
• Review findings/recommendations with the customer
• Make necessary repairs

Lift Truck Batteries (Semi-annually / Annually)

• Batteries should be pressure-washed to remove acid, corrosion, and other contaminants not removed by regular wipe-down
• Chargers (Semi-annually)
• Verify that chargers are correctly matched (AH rating) to batteries to avoid damage from over/undercharging
• 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 the ammeter
• Review findings/recommendations with the 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 the customer
• Make necessary adjustments/repairs

The above list is generic. Every application is different and requires a battery/charger maintenance program tailored to the user’s specific needs. 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 operate efficiently but will provide consistent, long-term performance that meets or exceeds your expectations and investment.

For more information, contact your local EnerSys Product Support Representative.