Protect your forklifts from corrosion and failure

Many people think of cleaning forklift batteries as purely cosmetic task, but it’s far more important than that. Acid buildup is a major threat. Corrosion between batteries can cause unwanted discharge and prevent the battery from functioning properly. This buildup can damage vital components, including battery partitions,  connectors, and cables, leading to costly failures.

Beyond damaging equipment, acid buildup can release harmful fumes as battery heats up. It can also cause skin irritation on contact. If left untreated, this buildup can lead to shorted battery cells, unusable batteries, or serious damage to the forklift itself. Proper cleaning helps protect your equipment, your team, and your bottom line.

What is acid build-Up?

Acid build-up occurs when battery acid escapes from the battery and collects between the cells. While it may look like ordinary dirt or grime, this substance is corrosive and harmful. It can discharge batteries even when  they’re not in use and weaken nearby components, leading to expensive repairs or even personal injury.

The dangers of neglect

Ignoring acid build-up can lead to serious problems, including electrical failure, potential battery explosion, reduced voltage and specific gravity (which signal deeper issues, and conditions that may require further testing or acid balancing. 

Overcharging

Overcharging or overheating are also dangerous: batteries should never be discharged below 80%. Repeated over-discharging shortens battery life, and low voltage combined with high amperage can produce excess heat, which may damage truck components like brushes and motors.

Corrosion

Corrosion is indicative of improper battery watering. If electrolyte is forced out of the cell, it can collect in the steel tray and cause deterioration of external components.  When water is added incorrectly, the electrolyte becomes unbalanced and lowers battery capacity. Methods to correct this problem include proper watering procedures, such as filling after charging, not before. A nebulizing system or automatic cell watering system can also help.

Cut cables

Cut cables are hazardous due to the risk of shorting. Shorted cables can cause personal injury if touched. Prevention measures include using insulated cable wraps as a temporary fix, but for a long-term solution, cables should be replaced. For safety reason, cable replacement should be performed by trained personnel only since molten lead and flames are used in this process. In addition, hydrogen gas is produced as a byproduct during charging, and is extremely explosive. Sparks are created as a result of damaged cables.

Broken or damaged connectors

Cracked or broken connectors can expose contact tips. This can lead to electrical shorting or even battery explosions, and should be corrected  as soon as possible.

Sulfation

Sulfation is a condition in which acid crystallizes on the battery plates. This creates resistance to the flow of electrolytes during charging and discharging, which prevents the battery from reaching full charge and capacity. If allowed to continue, the battery will no longer accept a proper charge. Monitoring charge levels, following correct charging procedures, and use the equalize function can help prevent sulfation. this condition often occurs when a charger is too small to  fully push the acid out of the plates,  or when the battery is left sitting unused and the equalize option is not used regularly–ideally once every five cycles).

Tray damage

Corroded or damaged trays can drastically weaken the structural integrity of the steel. This may lead to personnel injuries and expensive repairs may occur. Additionally, it  can cause issues with forklift truck compartments and components.

Inconsistent voltages and specific gravities

When abnormal voltages and specific gravity readings (i.e., acid concentration) are observed, problems are likely to occur in the near future. Testing may be required. Equalizing charges and acid “bouncing” (electrolyte movement and rebalancing may also be necessary.

Dry cells

If batteries are not properly watered and the electrolyte levels are too low, portions of the plates will become exposed. The exposed parts (not submerged in (electrolyte) will overheat during charge and discharge cycles.. This destroys the active material, significantly shortening battery life  and reducing capacity. Water levels should always be approximately a quarter of an inch above the splashguard. Only fill the water after charging–not before.

The solution

A complete battery cleaning neutralizes acid buildup. This process can be performed offsite using a self-contained portable washing station, which includes recovery of contaminated water. For batteries that cannot be removed from the equipment and when the total battery count is five or fewer, a hand-wash will be conducted. This service helps extend the life of your equipment and reduces the risk of unexpected breakdowns.