Forklift battery reconditioning is an ideal way to save hundreds and even thousands of dollars by avoiding buying a new battery.
Your forklift usually makes use of lithium-ion batteries. Some even use the old time lead-acid batteries.
If you use lead acid batteries in your forklift then, sulfucation forces it to get weak.
This not only reduces battery life but also leads to your forklift malfunctioning.
By minimizing sulfucation and regenerating the batteries, the overall life of your forklift battery is increased.
So, let us get to understand what all is covered in forklift battery reconditioning.
This write-up shall also discuss how and why this process helps you.
Forklift Battery Reconditioning Article Contents
1) What is a Forklift & How does it Work?
2) What are Forklifts Used For?
3) What are the Different Kinds of Forklift Batteries?
4) Why does Your Forklift Battery Die Down so Quickly?
5) Why is Forklift Battery Reconditioning Necessary?
6) How does Forklift Battery Reconditioning Work?
7) Conclusion
What is a Forklift & How does it Work?
I (LeanAndFit review staff) realize that this article is about reconditioning forklift batteries but first you should know what a forklift is. It is a small vehicle that has two forks extending from the vehicle. These forks help pick heavy objects and move them up or down.
Mostly used in industries for transporting goods from one place to another, forklifts are operated by a single driver. Forklift has a truck frame on which rests four wheels, mast and counterweight.
Here are the Components of a Forklift:
Forks: These are two in number and parallel to the ground. They are used for lifting the product.
Frame: On this rests the entire forklift including the wheels.
Wheels: The front two wheels are large in size whereas the rear two wheels are relatively smaller.
Engine Compartment: This lies right below the driver seat. It also contains the battery that is required to power the forklift.
Overhead Guard: This is in the form of a sheet of metal that guards the driver.
Mast: These are in the form of a pair of twin iron pillars. The mast is connected to the main carriage.
Lifting Chain: A crosshead is positioned on top of the twin masts thereby connecting them. In between the crosshead rests a small pulley. This pulley helps the lifting chain to operate the forklift.
Hydraulic System: This is in the form of the control mechanism for determining the fork movement. There is a special lever for operating the mast. This is located in front of the driver seat.
How does a Forklift Work?
The hydraulic cylinder intakes air from the electronic air pump, which is activated via the lift handle. As the gas volume increases, the pressure inside the tube increases.
This raises the piston attached to the tube affixed to the hydraulic cylinder. The piston moves upwards thereby reducing the pressure and increases the gas content. The force applied by the weight added to the forklift and gas is equated at the height at which the forklift is positioned.
To lower the weight loaded at the forklift, the operator simply pushes the leaves backwards. This enables the pent up gas to emit from the cylinder.
To lift the added weight on the forklift higher, the operator pushes the leaver forward. This action pushes more air into the hydraulic cylinder.
The chains further help lift or drop the weight added to the forks via a gear based mechanism. The function is similar to how the gear mechanism of your car functions.
How does the Steering and Lifting Controls of a Forklift Work?
>>> The Forklift Steering Compartment:
The forklift driving cabin is very simple indeed. This rear wheel drive machine consists of a steering wheel, a brake pedal, an acceleration pedal and two levers – one for going forward and the other for reversing.
>>> The Forklift Control Levers:
The forward and backward tilt leavers help lift the load either up or down via the forks. You can tilt the forks forward and backwards using these leavers.
Mast Forward: The forward tilt compels the forks to move forwards. When air fills the forklift chamber, the masts move forward owing to the pressure applied on them by the piston.
Mast Backward: When you push the reverse tilt leaver, the gas is released from the chamber and distributed to other vacant cylinders. This forces the piston to push forwards thereby pulling the mast back to the chamber.
What are Forklifts Used For?
As I have mentioned above, forklifts are mainly used for industrial purposes. You may have seen these vehicles plying up and down ports. They are capable of some heavy lifting putting their forks to good use.
Here are some of their common usages:
Shovelling Snow from the Yard: Forklifts have the ability to attach specially designed snow removing ploughs. These are then used to remove snow from your yard, the road, parking lots and other areas.
Moving Heavy Construction Materials: Forklifts are used to ferry heavy construction material in construction sites. They help unload brick, cement bags, concrete slabs from the trucks and transport them to the necessary designation.
The Dockyard: You may have seen forklifts operating day and night at the local dockyard. If you do not have access to a yard, you must have seen them on television. Forklifts ferry heavy containers from the trucks and then place them into the ship (and vice versa).
In the Warehouses: Forklifts are used in warehouse to place heavy cartons in place. Usually a 40 to a 60 ton capacity forklift is considered sufficient for the job. They carry goods to and from transport trucks.
The Garbage Dumps: Another use of forklifts is to work in garbage dumps. They carry sorted material to recycling plants. Railway cars as well as tractor trailers and trucks can be used for loading and unloading using forklifts.
What are the Different Kinds of Forklift Batteries?
Lead Acid: Like any other machine operating out of battery power, forklifts too work via lead-acid and lithium-ion batteries. Lead-acid batteries are heavy and old fashioned. They create power via the interaction of sulphuric acid and lead plates.
Lithium-Ion: This is the latest and most commonly used battery in forklift. There is no need for submerging it in water as the cells are sealed. These battery types are safe, light and require minimal maintenance. They are however more expensive as compared to lead-acid batteries.
Here are some pointers:
@ If your work involves canter riders or end riders then, opt for a 24 volt battery.
@ If you have a narrow aisle machine then, opt for a 36 volt battery.
@ If your work involves some heavy lifting for which you have a counterbalanced forklift then, opt for the 48 volt battery.
@ In case your work involves super heavy lifting then, you may use an 80 volt lithium-ion battery.
@ Lithium ion battery needs about an hour to get fully charged to last 7.5 hours. You can recharge it and reuse it.
@ Lead Acid batteries need a cooling off time period, which is equivalent to 7.5 hours after each usage.
@ Lithium Ion batteries are charged by plugging it directly to a charging point.
@ Lead Acid batteries need a special charging station. They need to be removed from the forklift and then charged at the designated charging station.
Why does Your Forklift Battery Die Down so Quickly?
There are many reasons why your battery dies out sooner than you expected it to. Let me walk you through a few such reasons:
@ If your forklift has lights and you left these on, your machine’s battery is bound to drain. Do ensure to switch these off when your forklift is not in use.
@ It is quite possible that you forgot replacing your forklift battery. It has been operating well for the past 4 years but now, it stalls. It is time to replace your old battery with a new one.
@ In case you use an alarm system, a watch or listen to music while the engine is not running, your battery is bound to drain. So, use these only when your battery is running.
@ If you are stopping and re-starting the engine way too often then, the alternator would not get ample time to re-charge your battery. This drains its power rather quickly.
@ In case your battery terminals or connections are loose then again, your battery shall die out way too soon. Damaged or corroded terminals inhibit flawless transmission of energy into your battery. This leads it to die out very soon.
@ The alternator issue is also a reason why your battery gets discharged rather quickly.
@ In case the temperature outside is freezing or simply too hot to tolerate then again, your forklift’s battery would get drained easily. Intense heat and cold can damage the battery permanently.
Why is Forklift Battery Reconditioning Necessary?
Battery sulfation is the prime reason why you need to recondition your batteries. This usually is a resultant of the forklift’s battery completely being drained. You do not always have to hire a refurbishing company.
So while it seems like a natural process, sulfation tends to leave behind sulphur compounds to latch onto the lead present within your battery.
This hampers a normal recharge. The result is more energy consumption while recharging the battery. If this continues to happen, your forklift battery is bound to die down.
So, in order to recover the operating capability of the damaged battery, battery regeneration is considered a wise and sensible option. The process removes lead sulphate, tightens terminals and eliminates corrosion of battery parts.
Tips to Prolong the Lifespan of Your Forklift Battery?
>>> You need to get your forklift battery to a workshop, at least once every year. The mechanics shall check for any signs of the sulphate crystals chocking the battery.
>>> Check and clean the battery terminals and other vital parts on a monthly basis. In case you are not the DIY types then, hire someone who knows this job well.
>>> The battery box should be checked for any uneven surfaces. The battery surface should be treated to avoid leakages.
>>> If you use a lead-acid battery then, you need to incorporate equalization and discharge balance.
>>> Periodically check the condition of the cells present within the battery. If they need a replacement then, go in for it without a second thought.
What are the Steps Followed in Forklift Battery Reconditioning Process?
While it may seem simple to look after a forklift battery, in reality, the task is slightly tough. This is owing to the careful maintenance that this battery type demands from its end users. Well, here are a few tips that can make your task easier:
The Vapor Cleansing
The very first step is to clean the battery via steam cleaning process. This is via a special spraying devise that emits boiling water in the form of steam.
The vapor thus emitted via the nozzle removes dirt, grime, allergens, staph and molds from the battery.
Equalize Charge on the Battery
If you are using a lead-acid battery for your forklift then, you need to run a stratification charge. This process also helps remove excessive sulfation by forcing sulfur ions to seep into the electrolyte again. The charging voltage is higher than the normally recommended voltage used for recharging the battery.
Electrolyte Gravity Check
The electrolyte gravity in a fully charged cell is 1.28 to 1.30. To prolong the battery life, simply use a hydrometer to lower the gravity. The 1.4 level is ideally suited for this purpose.
The Battery Discharge Test
Measure the AH capacity of the forklift battery in order to determine its efficiency level. 1.75 volts per cell is an ideal discharge rate for a lead-acid battery.
The discharge test should be performed for a period of 8 hours. This determines how many times a forklift battery can be recharged (after being discharged) before completely dying out.
Revive Dead Cells or Replace Them
If the cells of a lead-acid battery are damaged then, you can easily replace them. You can also perform de-sulphation to revive old cells. The process is lengthy and requires expert handling. A trained mechanic can do this job well.
Repair Cracks on Battery Jar
Wet batteries tend to cause battery acid to migrate and settle on the outer edge of the terminals/bolts. This causes the battery to discharge and bulge on the plates. These need to be repaired at the earliest to avoid mishap and prolong the battery life.
Cable and Connector Replacement
To avoid battery discharge and electrical faults, the cable clamps need to be checked and replaced if necessary. Cables of under charged batteries tend to corrode. You can clean them (battery cleaner sprays) or else replace them altogether.
Clean the Battery and Re-Paint if Necessary
Forklift batteries need to be kept clean and free from rust, corrosion and dirt. Batteries that are exposed to excessive heat, cold or moisture suffer from these issues.
Use lemon juice, vinegar, isopropyl alcohol and a microfiber cloth to clean the battery with. Once cleansed, repaint the battery so that it looks good as new.
Conclusion
If you detect faults in your forklift battery, you can be rest assured that its lifespan shall be prolonged. The advantages linked to maintaining your forklift battery are immense. Here is how you benefit:
@ The battery life of your forklift increases several folds over.
@ Your battery remains safe and free from avoidable mishaps.
@ The forklift machine is saved from avoidable damage.
@ The running time of your forklift is increased.
@ The motor of your machine is saved from damage as the battery is working flawlessly.
@ The productivity at work increases several folds.
@ You do not have to replace the battery and spend unnecessarily.
What happens if you avoid forklift battery maintenance?
@ The life span of your forklift battery shall definitely be reduced.
@ Lack of operationally functional batteries damage the lifting ears of a forklift. This can cause accidents.
@ The cells in an unmaintained battery tend to corrode. This may lead to leakage in the battery.
@ Forklift batteries that are not looked after tend to release volts into the earth. This causes power related faults.
@ The clothes of the person manning your forklift can get stained if electrolytes leak from within the battery.
>>> Click Here to Learn How to Recondition Your Forklift Battery at Home without Spending a Single Dime <<<
References:
- https://www.prolifttoyota.com/forklift-service/forklift-battery-reconditioning/