5 Important Electric Forklift Battery Maintenance Tips

July 05, 2022 - Last modified: July 26, 2022 @ 3:35 pm

Electric Forklift Battery

Now that you have purchased an electric forklift for your warehouse or construction project ensure that you care for your equipment appropriately so that it lasts. Consistent electric forklift battery maintenance is critical for extending the life of your forklift and its power source.

From user safety procedures to charging best practices, keep these five tips in mind to protect your investment and get the most out of your electric forklift and its battery.

1. Safety First

Heavy equipment batteries contain sulfuric acid, which can cause severe burns. So be sure to wear personal protective equipment with chemical-resistant properties when you work with the battery. Make sure that a hand and eye washing station are nearby so that you can access it quickly if any acid gets on your skin or in your eyes.

The Occupational Safety and Health Administration requires employers to provide the following protective gear when dealing with batteries:

  • Acid-resistant apron or jacket
  • Acid-proof gloves
  • Chemical splash shields
  • Chemical splash goggles
  • HAZ-MAT boots

Since you're dealing with electricity, remove any metal jewelry whenever handling or charging the battery. Metals are powerful conductors and can cause serious injury when coming in contact with an electrical current. Similarly, steel-toed shoes are a must when moving the battery from one place to another.

No one should perform electric forklift battery maintenance alone! These batteries can weigh up to 3,000 pounds, so use a walkie-pallet jack equipped with a transfer carriage to prevent injury when you and your team need to move the battery.

2. Schedule Electric Forklift Battery Maintenance

Setting up a schedule for your battery maintenance, complete with checklists and reports, can save time and money. As a result, your equipment will work more efficiently and last longer, ensuring a better return on your investment

Daily Tasks

  • Connect the battery to an automatic starter approved by the manufacturer.
  • Ventilate the battery by opening the cover and lifting the truck hood. 
  • Turn off the automatic charger before disconnecting the battery.

Weekly Tasks

  • Clean any visible residue with a neutralizing agent if needed.
  • Check battery electrolyte levels.
  • After charging, use a hydrometer to measure specific gravity, looking for an ideal measurement of 1.285.
  • If unbalanced specific gravity between cells, conduct an equalization charge with a sufficient cool-down period.
  • After charging, check water cells and add water if necessary.

Monthly Tasks

  • Scrutinize batteries for signs of corrosion on the terminals or damage to cables or connectors.
  • Remove any residue from the tops of battery cases using a neutralizing agent.
  • Repeat weekly charging procedures and equalization as necessary.

Every 3-6 Months

  • Recycle spent batteries.
  • Thoroughly wash batteries with a neutralizing agent and air dry. A battery wash cabinet can automate this process.

3. Charge Forklift Batteries the Right Way

Electric forklift battery maintenance best practices include timely and structured charging procedures. You can extend your battery's viability by following a set charging program based on how batteries work and the manufacturer's recommendations. 

Immediately stop using any battery that reaches the red zone, where only 20% of the charge remains. Continuing to use the forklift beyond that mark may damage your equipment's battery and electrical components due to overheating.

Also, charge your battery to 100% every time. Each battery has only around 1,500 charges, and the system can't tell the difference between a full and a half charge. So don't waste them with partial charges on a lunch break! Similarly, if a battery still has more than 20% power, don't charge it; run it down to the correct level, so you don't squander the charge you already used.

4. Monitor and Maintain Battery Temperature

Some forklift batteries are designed for extreme temperatures, but most standard batteries can lose performance if the local environment is not appropriate. For example, when temperatures fall to 30 degrees Fahrenheit, performance can drop 30%. Similarly, at temperatures above 92 degrees, battery performance can plummet by 50%.

Electric forklift battery maintenance procedures should involve carefully selecting the charging environment. Always charge your batteries in a climate-controlled area with a temperature between 50 and 86 degrees Fahrenheit. In hot locations, let the battery cool to room temperature or for about eight hours before charging it. 

5. Conduct Weekly Equalization Charges

The power capacities of the cells within forklift batteries tend to become unbalanced over time, so the battery won't fully charge. This imbalance leads to an inefficient and wasteful system. You'll be charging your battery more often while using up the limited charges without the benefit of a fully powered battery.

You can perform an equalization charge to combat this problem during a standard charging cycle. Equalization is the process of intentionally overcharging the battery to correct the imbalance. The process adds a three-hour stream of low-power to the standard eight-hour charging cycle. Since the maintenance team should complete the procedure every week, it requires additional cool-down time, so running it over the weekend may be convenient.

Equalization can also prevent "stratification" when the water and acid within the batteries' cells separate. The batteries release oxygen and hydrogen at the end of an equalization session, forming bubbles. These bubbles essentially stir the electrolytes and prevent stratification within the cells.

Consistent Electric Forklift Battery Maintenance Keeps Employees and Equipment Safe

You may have purchased your electric forklift to make your employees' jobs safer and more efficient, or you might need it for your construction projects. This equipment is a significant investment, and you want to keep it working at peak capacity. You also want everyone to stay safe during battery charging and use. Practicing electric forklift battery maintenance from the date of purchase to recycling time ensures that your lift truck battery will perform to the full extent of its power capacity.

For more information on choosing the best forklift for your project or business, contact our team at Forklift Inventory. We can help you select a forklift and offer additional advice about maintaining your equipment to stand the test of time.

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