Everything you need to know about forklift battery maintenance

DWE Training Services in Grangemouth is here to help keep your truck’s batteries in excellent condition.

Understanding the Challenge

It’s crucial to recognise the dangers and risks associated with the battery on your forklift or any electric MHE. How can we assess the equipment, and is it possible to reduce the risks of using electrical equipment without incurring excessive costs?

Forklift Battery Use and Maintenance

Every time you operate a forklift or other powered industrial truck, it’s essential to inspect it to ensure proper functioning. Ongoing battery maintenance is vital for the machine’s safety and reliability.

First and foremost, check that the battery has sufficient charge to complete the task. Forklift batteries are typically lead-acid or nickel-iron, charged by plugging the forklift into a fixed station or using an on-board charger. As the batteries contain corrosive chemicals that can cause burns to the skin and eyes, personal protective equipment (PPE) must be worn to prevent contact.

This should include:

  • Rubber gloves
  • Safety goggles and a face shield
  • An apron
  • Steel toe-capped boots to protect against
    crush hazards
During battery charging, flammable oxygen and hydrogen gases may be released, so it’s essential to choose and maintain the battery charging station with care to avoid injury.

  • Ensure the area is well-ventilated to prevent gas build-up
  • Mark the area with signage and floor striping to clearly outline the battery charging station
  • Provide emergency eyewash and shower stations near the charging area for acid splashes
  • Keep a spill kit with acid-neutralising materials, posted instructions, and firefighting equipment nearby
    Proper training in battery inspection, maintenance, and recharging procedures is essential.

Inspection should cover:

  • Correct fluid levels
  • Intact, insulated cables
  • Clean contact posts without crystallisation or corrosion
  • Any cracks in the casing

General Battery Maintenance Safety Tips

  • Ensure the forklift is off and the emergency brake engaged before charging
  • Turn off the charger before connecting or disconnecting it from the battery
  • Always add acid slowly to water; never add water to acid
  • Keep battery vent caps securely in place to ensure gases vent safely
  • Avoid open flames, sparks, and smoking near the battery charging station
  • Remove metal jewellery and keep metal objects away from the battery to prevent electric shock and burns
Batteries not only power the forklift but also provide counterweight. Weighing up to 900kg (2,000 lbs), it’s vital to follow best practices to avoid crush injuries when moving, changing, or manoeuvring batteries:

  • Only move the battery with properly rated equipment
  • Secure the battery during transport and in the forklift
  • Charging a forklift battery isn’t complicated, but it must be done with care.
  • Following safe practices can extend battery life and ensure there’s always enough power to complete the job.

Pro-Fill

With the Pro-Fill system, you can refill batteries without removing the vent covers, avoiding acid burns, ruined clothing, and harmful fumes. Each Pro-Fill valve features a flame arrestor, preventing the ignition of flammable battery cell gases. Pro-Fill is the safest and most efficient way to water your batteries.

Reliable

Using the Pro-Fill watering system ensures your battery is always filled to the correct level. Properly watered batteries last longer and perform better. Overfilling can lead to acid loss, while charging with low electrolyte levels can permanently damage the lead plates. Both issues reduce battery capacity and lifespan.

Contact DWE Training Services on 07769 553419 for expert advice on forklift battery maintenance.

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