Battery Service

Battery Charger Service includes:

• Name plate identification and verification
• Check A/C input / DC Output
• Check ammeter / proper calibration
• Check and adjust high-low rate control
• Inspect Rectifier / Transformer
• Visual Inspection of all connections
• Clean and lubricate moving parts
• Clean charger Inspect access door latches and hinge

Battery Cleaning is performed for more than just the visual appearance of the battery. We Neutralize the acid buildup which will reduce the amount of acid that traps in between cells. Acid buildup will corrode the battery cell walls, connectors, cables and may also cause damage to the lift truck’s battery compartment. This can lead to dead cells, shorted out batteries or lift truck component issues.

Overcharging… Batteries should not be discharged below the 80% discharged level, except in emergency situations. Continually discharging to 100% discharge level will reduce battery life. Low voltage and high amperage also effects truck components (contact, brushes and motors).

Corrosion… Corrosion is an indicator of improper watering of batteries. If electrolyte is forced out of the cell it will corrode and weaken the steel tray, as well as causing other external component deterioration. When water is added, the electrolyte becomes diluted and thus loss of capacity. Methods to correct this problem include employing proper watering procedures (filling after charge, not before) and utilize an automatic cell filler or watering system.

Cut Cables… Cut cables are hazardous because of the possibility of electrical arcing. The burning action of the shorted cables can cause great personal injury. Hydrogen gas is a by-product during the charge cycle and is extremely explosive. Preventative measures include installation of plastic cable wrap. New cables should be replaced by qualified personnel because molten lead and flames are used.

Broken or damaged connectors… Cracked or broken connectors allow the contact tips to be exposed. This can lead to electrical shorting and possible battery explosion and should be repaired or replaced as soon as possible.

Sulfation… Sulfation is a condition in batteries where sulfuring acid crystallizes on plates and causes a resistance, thus preventing full charge back. If allowed to continue the battery will not accept a charge. Monitoring charging procedure and utilizing the equalize can help prevent sulfation.

Tray Damage… Corroded or damaged trays can drastically weaken the strength of the steel. Personnel injury and expensive repairs may occur. This can also lead to lift truck compartment and component problems.

Inconsistent Voltages and Specific Gravities… When we see voltages and specific gravities (acid concentration) vary we can expect problems in the near future. Further testing may be required.

Dry Cells… If electrolyte levels are low enough a portion of the plates will be exposed to air. This allows for sulfation and reduced capacity. Water should be approximately ¾ of an inch higher than the splash guard. Though if cells were exposed to air there may be damage to the cell and testing should be considered. (Only fill water after charge, not before).

1. What is a forklift battery? A forklift battery is an electro-chemical device that stores D/C power for use in a forklift. It also acts as part of the forklift counterbalance.

2. How often should I water my battery? Check and adjust water to the proper levels only after the battery has received a full charge.

3. Why is the light on my battery flashing? This indicates water levels in the battery. Water needs to be checked and adjusted if necessary.

4. How often should my battery be cleaned? Typically, every 90 days or 60 days in extreme conditions.

5. When should I charge my battery? FAST CHARGE: whenever the truck is not in use. CONVENTIONAL: Daily for normal use. 2-3 times weekly for light applications

6. What is a battery monitoring device? This is used to record the battery/charger activities during usage. Information includes such items as i) The daily State of Charge. ii) Weekly EQ Cycles iii) Daily connections iv) Daily Usage (EBU). V) Operating Temperatures.

7. Why is my battery failing? Here are some of the more common reasons industrial forklift batteries can fail.