Forklift Battery Maintenance    2010-04-21

      A large percentage of forklifts are electric-powered. The batteries used in these machines are very reliable and also very expensive. Proper maintenance is required to extend the lifespan of the batteries and provide reliable power for the forklifts.

Charging

      Forklift batteries are designed for long life. The lifespan can be lengthened or shortened by which charger options you select. The battery should not be charged daily. This can harm the battery and prevent it from receiving a full charge. Only place the battery on the charger when it is at 20 percent power or below. Approximately every five to 10 charge cycles, you should select the equalize or weekend charge option. This will maintain the battery at top performance. Do not use this option too often, or damage may occur.

Water Levels

      It is imperative that a proper water level is maintained in the battery cells. It is recommended to check the water level every five to 10 charge cycles, depending on the age of the battery. Check a few random pilot cells using a flashlight. NEVER use a match, lighter or any other open flame near the battery. The gases emitted from the battery are extremely flammable. You should also wear protective gloves as well as eye protection when working with batteries. If the water is low, add enough water to cover the element protector. There will be some expansion during charging, so do not overfill the cells.

Discharge

      While you should not charge a battery when it is over a 20 percent power level, you should also not allow the battery to completely discharge either. Allowing the battery to completely discharge, or deep discharge, can result in damage not only to the battery but also to the electronics on the forklift. A deep discharge can also make it impossible for your charger to completely charge the battery during a normal cycle. This will shorten the time between charges, and over time it will affect the performance of the battery.