Learn All About Forklift Battery

Learn All About Forklift Battery 

Forklift Battery Properties

Batteries Forklift batteries use lead batteries.
Electric energy can be stored as chemical energy (= charge), and taken out as electrical energy whenever necessary (= discharge), and can be repeated.
Generally, two types of batteries, 24V and 48V, in which 12 or 24 2V battery cells are connected, are the mainstream.
Batteries for battery forklifts are expensive, but their life will be different due to daily maintenance.

General features Battery life:

75% use at 20 ° C, 1,200-1,500 cycles
Electrolyte : Temperature (ambient temperature: 20 ° C) 1.280 ± 0.005
Discharge end voltage : 1.70V

Forklift battery life

Although it depends on the usage environment, according to the data released by the JIS standard by the manufacturer, it is said that the life is 1,200 to 1,500 cycles with one cycle of charging and discharging.
For example, if you charge the battery once a day, you will not be able to use it due to sulfation  on the electrode in 240 cycles of 5 to 6 years.
However, the physical endurance is said to be 2,000 cycles, and it is a battery that has been prolonged to the life of the regenerated battery often heard in the market these days.
For example, if you regenerate a battery that has been charged and discharged for 1,200 cycles, you can charge and discharge the remaining 800 cycles.

(sulfation) This is a phenomenon in which fine particles of lead sulfate dissolved in the electrolytic solution become saturated and crystallize when the temperature of the electrolytic solution falls, forming lead sulfate and adhering to and multiplying on the electrode plate.
This is a deterioration phenomenon that occurs when a battery is used for a long period of time, and most of the causes are caused by this, except when the battery fails due to physical damage.

Maintenance

It is said that the battery life is determined by the number of times charging and discharging are repeated and the discharging time.
However, neglecting daily maintenance naturally shortens battery life.

The most basic maintenance is regular replenishment of the battery make-up water .
Especially in the summer and in places with high temperatures due to the work environment, frequent replenishment water checks are required.

Daily handling method

1. Over discharge prevention

Please supplement the charge so that the voltage does not fall below 20% of the total capacity. Over discharge (low voltage) can shorten the life of the storage battery.

2. Overcharge prevention

Be careful not to let the electrolyte temperature exceed 50 ° C during charging.
If the temperature exceeds 50 ° C, stop charging immediately, wait until it becomes 40 ° C or less (reduce the charging current, and watch for temperature rise),
then restart charging.

3. How to charge

Do not charge the battery frequently, and do it all at once when the remaining battery voltage is 30 to 35% of the total capacity.
Frequent short-time charging may shorten the life of the storage battery.

4.Replenishing purified water

Check the electrolyte solution before and after each charge.
Before charging, maintain the minimum liquid level, and if the liquid is insufficient after charging, add an appropriate amount of purified water.

5. Maintenance of cleanliness

Foreign matter such as electrolyte may get on the battery cover, cell box, and terminal dissolution area, which may cause self-discharge.
Carefully remove foreign matter and always keep it clean.

6. Other

For all storage battery handling methods, follow the manufacturer's and seller's instructions.
(Regarding matters that occur due to use outside the setting, it is not covered by the warranty)

About replenishing the battery

The final life of the battery will be up to the physical durability of the electrode, but the deterioration of the battery will accelerate depending on the usage environment and daily maintenance.
Users who feel that the battery life is short are often not properly maintained.

There are three main causes that adversely affect the battery .

・ Draining

・ Overcharge

・ Over discharge

It is necessary to finally visually check whether or not each cell is properly refilled, without over trusting the batch replenisher.

Since the white line is visible, it is in
a state where the liquid is sufficiently filled.

I can't see the white line because the float sinks.
Please replenish water.

Although replenishing the battery fluid is time consuming, it is possible to extend the life of the battery originally
by performing reliable maintenance on a regular basis.

Symptoms of the time battery-powered battery replacement for

1.reduced operating time

Example: What used to be 6 hours in the morning and afternoon, but now only 2 hours.

2. Increasing rate of decrease in battery gauge

The battery gauge showing the battery capacity decreases more quickly.
Example: Only 1 memory was reduced after running for 1 hour, but 2 memory or more was reduced at the same running time.

3. Low battery power

Example: It took longer to unload as the discharge power decreased.

4. Battery body heat generation

The battery itself generates excessive heat during operation and charging. (Influence of sulfation)

5. Battery fluid evaporates quickly

Since the battery body generates heat, the battery fluid evaporates faster.

Battery handling precautions

Please be sure to observe!

1. Please check and record the specific gravity, voltage, temperature, etc. of the battery on a daily basis.
2. Keep the top of the battery cover clean and dry. (Prevention of leakage)
3. Sulfate on the cell terminals should be carefully removed with hot water and coated with a rust preventive agent to prevent corrosion.
4. Keep the cell vent plug (cap) closed at all times. (Forbidden entry of foreign matter)
5. If there is a variation of 0.02 or more in the specific gravity of each cell, perform uniform charging.
6. It depends on the frequency of use, but the guideline is as follows.
7. Summer: 1 time / month Winter: 2 times / month (correction of non-uniform condition of each cell to prevent failure)
8. Be sure to charge the battery in a well-ventilated and cool place.
9. After charging the battery, remove the charger and plug of the electric vehicle and store it in a cool and dry room.
10. If a defective cell is found, replace it immediately.
11. Be sure to wear protective equipment when performing maintenance or repair work such as supplementing purified water. (Protective glasses, rubber gloves, rubber boots, aprons, etc.)
12. If the electrolyte should come into contact with your eyes or clothing, wash it off thoroughly with plenty of water and seek medical advice from your eyes and skin.
13. Keep the electrolyte above the specified minimum liquid level.
14. For the replenishment of purified water, please replenish an appropriate amount after charging is completed. (If replenished in a large amount, the specific gravity may decrease and the performance may decline.)