The truth is, your forklift is only as good as its battery. When that battery dies, your operation comes to a standstill. How long will it take for you to get moving again? There’s a way to know for sure.
I’ll give you everything you need to know about forklift battery charging. Here’s what we’ll cover:
- What makes your charging time longer (or shorter)
- The lowdown on different battery types and charging requirements
- When to charge your forklift battery (the ideal time)
- Things to check before you charge (so you don’t miss anything important)
Are you ready to become a forklift battery expert? Let’s get started.
Let’s Talk About What Affects Charging Time
There is nothing more frustrating than having to wait for your forklift battery to charge. But what exactly impacts charging time? Here’s what matters so you can make the most of your charging time.
- Battery Chemistry: Battery chemistry is the first thing to consider. Think of it like choosing a race. Lead-acid batteries are like marathon runners. They are steady and consistent, but they take their time. Lithium-ion batteries are like sprinters.
- Battery Age and Condition: You know how sometimes your old phone battery runs like it’s stuck in molasses? The same thing can happen with your forklift battery.
- Depth of Discharge (DOD): This one’s pretty self-explanatory – the less full your battery is, the longer it’ll take to recharge. It’s like your gas tank – if it’s empty, you’ll need to fill it up all the way before you can hit the road.
- Forklift Battery Charger Type and Output: You wouldn’t use a charger meant for a phone on a laptop, would you? Same thing here. Using the wrong one, or one that’s not powerful enough, can slow down the charging process.
- Ambient Temperature: Batteries can be a bit finicky when it comes to temperature. If it’s too hot, charging slows down. If it’s too cold, charging might not work at all. Keep them at room temperature, and they’ll charge just fine.
Types of Batteries and Charging Strategies
There are several types of forklift batteries. Each battery type has its own charging characteristics, much like people have different personalities. Knowing your battery type is important and essential for battery maintenance.
- Lead-Acid Batteries: Lead-acid batteries are the most common battery types. They are the least expensive in terms of initial capital investment. They require periodic watering and they charge slowly typically in the range of 8-12 hours. Lead-acid batteries are most efficient when charged to 100%.
- Lithium-Ion Batteries: These are the latest technology and offer a high capacity. The fast charging time is 1-2 hours and the batteries are self-maintaining, meaning they don’t require a lot of upkeep. They’re also quick to charge between shifts. The downside is that lithium-ion batteries are more expensive.
- Absorbent Glass Mat (AGM) Batteries: AGM batteries fall somewhere in the middle. They're part of the lead-acid family, but they're sealed and don't require maintenance. They're faster to charge than their lead-acid counterparts and can be deep-cycled as well. They're a good compromise if you need some of the benefits of newer batteries without the price tag.
Don't play guessing games with your battery's charging needs. Always check your manufacturer's specs—it's crucial to get the exact requirements for your model.
Need to Charge Your Forklift Battery? Here's When to Plug In
You may think this is a no-brainer, but knowing when to charge your forklift battery is a crucial part of extending the life of your battery. In this analogy, the battery is like your phone battery. If you wait too long to plug in your battery, the battery will continue to work but you could be reducing the lifespan of the battery and creating costly maintenance issues down the road. Here's what you need to know:
- Lead-Acid Batteries: These are the high-maintenance friends of the battery world. Keep them happy by charging them after every shift, even if they're not completely drained. Try to plug them in before they hit a 20% charge—they get pretty grumpy below that mark, and it can cut their life short.
- Lithium-Ion Batteries: The modern battery is a bit more flexible. You can give it a quick top-up during breaks or lunch, and it'll actually prefer that to a full charge. So that's a nice bonus.
- AGM Batteries: These batteries fall somewhere in between. They're less strict than the lead-acid batteries about quick charging, but they'll still appreciate a full charge after the shift. You don't have to be too strict, but you shouldn't be in the habit of running them down.
- The Golden Rule: When it comes to battery type, don't discharge it to 0% on a regular basis. It's like running a marathon a day—it's just too stressful on the battery and it will reduce the battery lifecycle.
The best resource for guidance is typically the battery manufacturer. They have an intimate knowledge of the battery and will be able to provide the most accurate guidance on how to optimize the battery lifecycle for your specific system.
How to Prepare Your Forklift Battery for Charging
Preparing your forklift battery for charging is one of the most important steps to avoid any damage to your equipment. It may take a few minutes, but it’s worth it to save you from any trouble later on and make the battery last longer.
- Protect Your Self: Before you begin, make sure you’re wearing your safety gear. You’ll need your gloves and eye protection. Forklift batteries contain harmful elements that can cause burns if not handled properly.
- Take a look: You should take a look at the battery itself. Is there any sign of cracks, leaks, or loose connections? If anything looks out of order, do not charge it, and get a professional to come and look at it. You do not want any accidents, even if it takes longer to get your work done.
- Check the level: If it is a lead-acid battery, you will have to check the electrolyte level. The plates should be fully covered with the electrolyte. If they are dry, then you will need to add some distilled water – but you should not overfill the battery. It is important to note that you should not use tap water, as your battery will not like that.
- Dirty Terminals? Clean Them: Your battery terminals should be spotless. Got some buildup? Mix baking soda and water to clean it up. Clean terminals charge better – it’s that simple.
- Give It Air: These batteries need to breathe while they’re charging. Especially the lead-acid kind.
- Match Your Charger: Don't even think about using the wrong charger. It could end up turning your battery into a very expensive brick, or even a fire. Literally.
- Unplug and Unwind: Unless the charger specifically tells you it's okay to charge with the forklift still connected, take the battery out of your forklift first. Your forklift's electrical system will thank you.
Let's Keep Those Forklifts Powered Up
There are different types of batteries, and each one has its own unique personality (and charging requirements):
- Older batteries require a little more care during charging
- If you treat your batteries right, they'll treat you right by lasting longer
- Battery safety is important—be careful out there
- If you're unsure, consult your manufacturer's manual
Now that you have a better understanding of charging basics, you're in a much better position to keep your fleet running efficiently. Good charging practices can help your forklifts spend more time moving product and less time waiting, which is great for your bottom line.
