Umair Gaines
Electric forklift batteries are expensive and can be reconditioned instead of replaced. The process is similar to servicing a regular 12-volt automotive battery, but more complex. Before recharging a forklift battery, it should be discharged to avoid overcharging, which can permanently damage the battery. The acid-to-water ratio should then be checked, and any issues with the cells should be addressed. The terminals should be cleaned with baking soda and water, and the battery should be filled with 30% sulfuric acid and 70% distilled water. This process should be performed monthly to extend the life of the battery.
Reconditioning an Electric Forklift Battery
| Characteristics | Values |
|---|---|
| Difficulty | Harder than reconditioning a car battery but not impossible |
| Complexity | More complex than a car's lead-acid battery |
| Safety | High voltage can cause death or severe burns and injuries |
| Procedure | Discharge, clean terminals, replace fluids, remove sulfation |
| Tools | Voltmeter, protective clothing, gloves, goggles, soft-bristle brush |
| Charging | Avoid overcharging, may need multiple cycles |
| Fluids | 30% sulfuric acid, 70% distilled water |
| Alternative | Drain and recharge with opposite polarity |
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What You'll Learn
Discharge and recharge
Before attempting to discharge and recharge your forklift battery, it is important to prepare the battery and the surrounding environment. Firstly, ensure that the battery is removed from the forklift and placed in a well-ventilated area. Next, prepare a voltmeter to check the voltage of the battery. Compare this voltage to the voltage on the battery's label.
Once you have noted the voltage, you can begin to discharge the battery. It is recommended to discharge the battery to 80% of the voltage displayed on the label. This process may need to be repeated a few times to ensure the battery is fully discharged before recharging.
After discharging, you can proceed to clean the terminals of the battery. Apply baking soda to the terminals and the top of the battery. Then, wet the surface with water and use a soft-bristled brush to clean the area. This process will neutralise any acid on the surface of the battery. It is important to wear protective clothing, gloves, and goggles during this step to avoid contact with corrosive acid.
Now, you can begin the recharging process. If your battery is a "wet" battery with removable cell caps, check the electrolyte levels and add water if necessary before charging. If the battery has been sitting unused for a long period, charge it gently and allow it to rest if the cells are not equalizing.
For batteries with significant sulfation, a process of equalization can be used. Charge the battery at 15-16V for 4-6 hours to dissolve sulfation. Monitor the battery temperature during this process, ensuring it does not exceed 125°F to prevent warping.
After equalization, top up the cells with distilled water to a level just above the plates. Then, perform load testing to verify that the battery capacity reaches 80% or more of its original rating.
It is important to note that discharging and recharging a forklift battery may require multiple attempts and a significant amount of time. The process can be complex, and if you feel uncomfortable at any point, it is best to consult a professional for assistance.
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Clean terminals
To clean the terminals of a forklift battery, you must first discharge the battery to the right level. Next, put some baking soda onto the terminals and on top of the battery. Wet the surface with water and brush it with a soft-bristled brush. Baking soda neutralises any acid on the surface, but you should still wear protective clothing, gloves, and goggles. Battery acid is corrosive, so avoid touching it with your bare skin. If baking soda doesn't remove all the dirt, use some dishwashing detergent to cut through any remaining grime.
To access the water inside the battery, remove the cell caps. The ideal composition of battery water is 30% sulfuric acid and 70% distilled water. Be very careful not to short-circuit any tools or your body to metal when working on these batteries, as the stored voltage is very high and can cause severe injury or death. Do not wear any metal jewellery while working on high-voltage direct current batteries.
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Remove sulfation
Sulfation is the buildup of lead sulfate crystals on the battery plates, which can eventually lead to a loss of cranking power and longer battery-changing times. This can happen when batteries are left discharged for too long, causing the lead sulfate to become hard and resistant to recharging. To prevent sulfation, it is important to recharge discharged batteries as soon as possible.
There are some products available that claim to remove sulfation buildup and extend the life of forklift batteries, such as Battery Chem™. To use this product, add the missing water from the cells, then add one cup of Battery Chem™ per cell, followed by a full charging session.
Another method to remove sulfation is to use a specialised charger. These chargers first drain the battery completely, then recharge it with opposite polarity, causing the sulfation to fall off the plates. The battery is then drained again and recharged with the proper polarity.
If you recognise sulfation early, an experienced professional may be able to reverse it. One indication of soft sulfation is when a fully charged battery can hold a stable voltage on discharge. However, if the voltage drops rapidly, the battery likely has hard sulfation. In this case, you may need to purchase a new or refurbished battery.
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Check acid-water ratio
Checking the acid-water ratio is an important step in reconditioning an electric forklift battery. Forklift batteries are deep cycle batteries, which means they can be discharged to a very low level without sustaining damage. However, if the battery is severely depleted or damaged, reconditioning may not be possible, and it may be necessary to replace the battery or seek professional help.
Before attempting to recondition a forklift battery, it is important to discharge it to the right level and clean the terminals to ensure safety and avoid permanent damage. This can be done by applying baking soda to the terminals and the top of the battery, wetting the surface, and then brushing it with a soft-bristled brush. It is important to wear protective clothing, gloves, and goggles during this process, as the battery acid is corrosive and can cause skin irritation or injury.
Once the terminals are clean, the cell caps can be removed to access the water inside the battery. The ideal composition of the water inside a forklift battery cell is 30% sulfuric acid and 70% distilled water. It is important to note that filling the cells to the top with distilled water can dilute the sulfuric acid too much, so it is recommended to fill them a little, charge them, and then fill them a little more if needed.
After adjusting the acid-water ratio, the battery can be charged fully. However, it is important to first ensure that the voltmeter readings are normal. If the cells do not pass a load test, there may be an issue with the cells themselves, and a professional may need to replace or recondition them.
By following these steps and checking the acid-water ratio, it is possible to recondition an electric forklift battery and extend its life, saving on replacement costs. However, it is important to approach the process with caution and be aware of the potential risks, as the stored voltage in forklift batteries can be very high and dangerous.
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Replace fluids
The process of reconditioning a forklift battery is more complex than reconditioning a car's lead-acid battery. However, it is not impossible to do it yourself. One of the leading causes of lead-acid battery failure is sulfation. When a battery is not used, sulfate crystals begin to form and can deposit on the negative plates of the battery.
To replace the fluids in a forklift battery, follow these steps:
- First, discharge the forklift battery to the right level.
- Then, remove the cell caps to access the water inside the battery.
- The battery water should be a mixture of 30% sulfuric acid and 70% distilled water. Do not fill the battery to the top with distilled water, as this will dilute the sulfuric acid too much.
- Fill the battery a little, then charge it, and fill it a little more.
- If the battery does not hold a charge, consider upgrading to a used set of batteries from hybrid cars, which are cheaper and can last twice as long as lead-acid batteries.
It is important to be very careful when working with forklift batteries, as the stored voltage is very high and can cause severe injury or death. Always wear protective clothing, gloves, and goggles, and remove any metal objects such as rings or bracelets before handling the battery.
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Frequently asked questions
The process of reconditioning an electric forklift battery involves several steps, including cleaning the battery, replacing fluids, and removing sulfation buildup. It is similar to reconditioning a car's lead-acid battery but more complex due to the larger size and weight of forklift batteries.
To clean an electric forklift battery, first, discharge it to the right level. Then, apply baking soda to the terminals and on top of the battery. Wet the surface with water and brush it with a soft-bristled brush. Finally, rinse the battery with water to remove any remaining residue. Always wear protective clothing, gloves, and goggles when handling forklift batteries, as the acid can be corrosive and dangerous.
If your electric forklift battery is not holding a charge, it may be due to sulfation buildup, a common issue with lead-acid batteries. You can use a voltmeter to check the voltage of each cell and identify any faulty or damaged cells. If the ratio of acid to water is correct, and the cells are still not holding a charge, the issue may lie with the cells themselves, and professional reconditioning or replacement may be necessary.
