Impact Handling’s Top 10 Tips: Lead-acid
battery maintenance
A good fork lift truck battery maintenance
regime will maximise productivity,
enhance site safety and help minimise
fleet costs. So here is our top ten list of
the everyday things fleet managers and
operators can do to get the most out of
lead-acid battery powered equipment.
1) Monitor levels
Maintaining the correct battery fluid
levels is an essential part of extracting
the full performance potential from any
battery. Levels should neither be too low
nor too high – top up the cells so that the
plates and separators are just covered
by electrolyte. Battery manufacturers
recommend that levels are regularly
checked. Doing so will also help prevent
premature damage or failure. Always
make sure that only distilled, de-ionised
water is used when topping-up any lead
acid battery.
2) Top-up AFTER a charge and
NOT before
As the water in batteries is critical to the
transfer of energy, the introduction of
fresh water must occur at the correct
time during its charging cycle, which
is after the battery has completed its
charge and never before.
Electrolyte expands when it gets warm so
topping up before a charge can result in
4) Allow batteries to fully charge
Doing so will keep them in optimum
Batteries will always perform best after a condition and allow the battery to deliver
full charge. its maximum capacity for longer.
Avoid the temptation to partially charge Newer machines are also programmed
them, or to interrupt a charging cycle. to cut out the hydraulic function when
80% discharge is reached, preventing
Doing so could damage the battery lift, however drive functions remain
permanently, reducing its capacity as well unaffected.
as potentially shortening its life.
5) Let batteries cool
7) Check Cables, plugs and
chargers
spillage of electrolyte. A typical lead acid battery needs to be left Battery leads can be prone to damage
for a good two hours to cool after every or corrosion, as can plugs and chargers.
3) Ensure battery and charger
compatibility charge. Build this time into your charging Check all equipment and connections
schedule and make it a mandated part of and report any frayed wires or worn
your health and safety best practice. insulation.
6) Keep an eye on the BDI A weekly visual inspection will help
There is an important difference between
a charger that simply works and one that
is specifically designed to correctly charge
a given type and make of battery. Check
with battery suppliers to confirm that the
correct charging equipment is being used.
Using incorrect chargers can be extremely
dangerous, can damage batteries and
may also compromise insurance cover.
Always follow the charging procedure
shown in your charger’s manual.
4 FDPP - www.fdpp.co.uk
Equipment operators should continually identify any issues before they can affect
monitor the status shown on Battery the operation of the machinery.
Discharge Indicators.
8) Use batteries evenly
Batteries should ideally be recharged When operating more than one battery,
when their indicator shows around 25% such as in multiple shift environments,
charge remaining. make sure that they are all used and
charged evenly.