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Forklift Battery Troubleshooting (Part 5) – Electrolyte Problems

Forklift Battery Troubleshooting (Part 5) – Electrolyte Problems

Key issue: Low Electrolyte Level / High Water Consumption   Cause: Leaking cell jar Solution: Replace cell Cause: Overcharging Solution: Check charger Cause: Shorted cells Solution: Identify and replace Cause: Neglect of topping up Solution: Top up the battery Cause: High temperatures (charging / operating) Solution: Charge the battery in cooler location Cause: Battery at the end of its life Solution: Replace the battery   Key issue: Elevated Electrolyte Temperature  Cause: Overcharging  Solution: Check charger / charger settings Cause: Low water level Solution: Top up the battery Cause: Shorted cells Solution: Identify and replace See also: Forklift Battery Troubleshooting (Part 1) – Performance Problems Forklift Battery Troubleshooting (Part 2) – Overheating Problems Forklift Battery Troubleshooting (Part 3) – Irregular Voltage & Electrolyte Density Problems Forklift Battery Troubleshooting (Part 4) – Battery Overheating during... read more
Forklift Battery Troubleshooting (Part 4) – Battery Overheating during Charge

Forklift Battery Troubleshooting (Part 4) – Battery Overheating during Charge

Key issue: Battery overheats on charging Cause: Incorrect charger settings Solution: Check the charger parameters Cause: Poor ventilation Solution: Open battery cover and use fan while charging  Cause: Shorted cells Solution: Identify shorted cells, replace  Cause: Low electrolyte level (Possible loss of capacity)  Solution: Top up with water  Cause: Sulphated battery Solution: Perform desulfation routine on the battery. (Extended charges with low charge currents) See also: Forklift Battery Troubleshooting (Part 1) – Performance Problems Forklift Battery Troubleshooting (Part 2) – Overheating Problems Forklift Battery Troubleshooting (Part 3) – Irregular Voltage & Electrolyte Density Problems Forklift Battery Troubleshooting (Part 5) – Electrolyte... read more
Forklift Battery Troubleshooting (Part 3) – Irregular Voltage & Electrolyte Density Problems

Forklift Battery Troubleshooting (Part 3) – Irregular Voltage & Electrolyte Density Problems

Key Issue: Uneven voltages and electrolyte densities Cause: Regular overdischarging  Solution: Do not discharge the battery below 80% DOD Cause: Neglect of equalizing Solution: Give the battery an equalizing charge on a weekly basis Cause: Dirty battery top (External shorts) Solution: Clean, wipe dry after charging Cause: Internal shorts Solution: Check cells for short circuits if the battery runs down regularly or replace Cause: Loss of electrolyte Solution: Perform equalize charge or return to manufacturer for electrolyte gravity correction See also: Forklift Battery Troubleshooting (Part 1) – Performance Problems Forklift Battery Troubleshooting (Part 2) – Overheating Problems Forklift Battery Troubleshooting (Part 4) – Battery Overheating during Charge Forklift Battery Troubleshooting (Part 5) – Electrolyte... read more
Forklift Battery Troubleshooting (Part 2) – Overheating Problems

Forklift Battery Troubleshooting (Part 2) – Overheating Problems

Key Issue: Battery overheats on discharge Cause: Incorrect battery sizing (undersized) Solution: Install proper battery both in terms of the forklift and its duty cycle  Cause: Electrolyte level low Solution: Top up or increase top up frequency  Cause: Lift truck’s mechanical or electrical problems Solution: Check and repair vehicle Cause: High ambient temperature Solution: Recharge and store the battery in cooler environment  Cause: Shorted cell Solution: Check the battery for shorted cells. Replace if necessary Cause: Current leakage to ground Solution: Check the insulation of the battery as well as for electrolyte in the container See also: Forklift Battery Troubleshooting (Part 1) – Performance Problems Forklift Battery Troubleshooting (Part 3) – Irregular Voltage & Electrolyte Density Problems Forklift Battery Troubleshooting (Part 4) – Battery Overheating during Charge Forklift Battery Troubleshooting (Part 5) – Electrolyte... read more
Forklift Battery Troubleshooting (Part 1) – Performance Problems

Forklift Battery Troubleshooting (Part 1) – Performance Problems

Key Issue: Forklift battery does not work full shift   Cause: Incorrect battery sizing  Solution: Install proper battery both in terms of the forklift and its duty cycle  Cause: Battery not fully charged  Solution: Check duty/recharging schedule/charger operation. Note: Do not use partially charged batteries for full shifts  Cause: Cell(s) removed from the battery Solution: Replace as soon as possible  Cause: Lift truck’s mechanical or electrical problems Solution: Check and repair vehicle Cause: Electrolyte contamination Solution: Check for the contamination source. Replace electrolyte or replace cells Cause: Short circuited cell(s) Solution: Identify by measuring voltage, specific gravity, temperature. Remove and replace cells  Cause: Battery at the end of its life Solution: Perform a capacity test (C5). If the battery performs less than 80% of its nominal rating, replace Cause: Electrolyte loss or electrolyte low level  Solution: Check the usage and the maintenance of the battery See also: Forklift Battery Troubleshooting (Part 2) – Overheating Problems Forklift Battery Troubleshooting (Part 3) – Irregular Voltage & Electrolyte Density Problems Forklift Battery Troubleshooting (Part 4) – Battery Overheating during Charge Forklift Battery Troubleshooting (Part 5) – Electrolyte... read more