Battery Maintenance – Make Your Battery Last!

Battery maintenance is extremely important; regular maintenance and checks will help reduce costs, improve safety and lengthen the life span of your forklift and its battery!

DO’s

• Always use a compatible charger.
• When connecting or disconnecting charger and battery plugs, always use the handles – NEVER PULL ON THE CABLES.
• Check the plugs and leads for damage on a daily basis. Report any damage or missing components, such as battery caps, to your Supervisor immediately.
• Always fill out the “Daily or Pre-Shift Checks” in the book provided on the machine. Electrolyte levels, cable connections, general cleanliness and a secured battery check are all part of the checks.
• Always charge a battery in a well ventilated area
• Store charger cables in a safe place.

DONT’s

• Do not OPPORTUNITY CHARGE or as this will significantly reduce the life and effectiveness of the battery
• Never interrupt a charge cycle if it is unnecessary. Once a charge has started, it should be be allowed to finish.
• If you have to regularly interrupt a charge cycle, inform your line manager
• Don’t OVER-DISCHARGE (discharge beyond 80%) the battery. This will significantly reduce the life expectancy of the battery.
• Don’t let a discharged battery sit there for extended periods. This will promote hard sulphation and significantly reduce the run time and life of the battery.

Battery Topping

• Always wear appropriate PPE – If in doubt, check with your Line Manager.
• Check water levels on a regular basis. If the battery needs topping up, the electrolyte levels should be topped to no more than 10mm above the plates. The additional space is needed for expansion while gassing at the end of the charge.
• Top up battery with distilled, de-ionised or approved water after charging only. Never top it up before beginning a charge.For batteries that have Autofil kits fitted, these must also be topped up at the end of charge, never before.
• Be on the lookout for split pipes or leaking joints – if you see one, stop topping and report the fault to your line manager.
• Never over fill as it will cause overflow on the next charge. An acid loss will inevitably shorten overall running time, can cause overheating and will require a shop service to rectify.

Battery Cleaning

• Cleaning your forklift battery is essential in prolonging its life.
• Always wear appropriate PPE – If in doubt, check with your Line Manager.
• Clean the battery top on a regular basis with “Battery Cleaner with Acid Indicator” The spray will turn pink in the presence of acid. After acid is neutralised the product will turn back to its normal light yellow colour. Use a clean cloth to wipe away all residue.
• If a battery over spills wash it immediately with water to stop corrosion on top of and underneath the battery. Use an adequate amount of water to dilute the acid so it is not environmentally harmful.
• The spilled acid is highly conductive and caustic. If not cleaned away immediately, the conductivity can negatively deteriorate battery life (even when not in use) and produce extra heat during recharge.
• If in doubt, talk to your line manager.

If this has helped you and left you feeling like you need to take more care of your equipment, check out our Battery Maintenance ‘start-up’ kit which contains everything you need to keep your battery maintained!

For more information or professional advise, you can contact us on 01392 46 46 56 or email us at info@westexegroup.co.uk.

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