Things to pay attention to when working with forklift batteries

In the previous post of samcovina.com, we have guided the design standards of a safe battery charging room/station for forklifts. Today, we suggest a few more safety tips when working with industrial batteries.

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Absolutely do not smoke, create sparks, open flames or solder near the battery chargerThis being clear, if there were any open flames or sparks near a battery charging station that would be an easy fire hazard, possibly resulting in a large explosion.
Make sure the battery cover is open while charging
Charging the battery will emit hydrogen gas during charging, opening the battery cover fully vented is necessary to disperse the gases otherwise it can compress in high concentrations and become a flammable place. Opening the battery cover will provide adequate ventilation.
Keep valve cover (vent) during filling (charging)
The valve covers all have vents that allow air to escape. If the valve cap is opened or removed, drops of acid and water will form on the top of the battery causing an electric shock, which will affect the battery’s frame. This can make it difficult to track down problems.
Always turn off the charger before disconnecting the battery
It is imperative that all chargers are turned off before you disconnect a battery as direct electricity can spark and become a source of ignition.
Never remove the battery by pulling the cord, always hold the latch and remove the charging plug.
Pulling the lead out of a battery unit will eventually damage the lead.
Always allow charging to complete one charge cycle
Disconnect a battery unit before a charge cycle is complete (full charge of one battery will continue to charge the next, to avoid overcharging). When using a standard charger – it can damage the battery performance, which in turn reduces the overall life of the Battery. It’s best to ask the seller for the correct charger that’s specific to the type of forklift you’re buying, not a universal charger for all batteries.
Make sure the battery charging head is clean and dry at all charges
It is imperative that the tip of the battery be clean and dry at all charges, if it gets wet when connecting to charge it becomes a high electric shock hazard. The battery will also self-discharge due to voltage monitoring. This may result in a non-rechargeable (unconnected) battery condition when returning to the extended shutdown phase. Having clean charging points also ensures a proper charging connection and is maintained with correct battery charges.

Never discharge a battery below 80% of its capacity/ learn more:
When a battery is discharged beyond 80% of its life (life cycle) decreases significantly, instead of a life span lasting at least 5 years (1 change only, 5 days/week operation), your battery may only last 2 years. Furthermore, discharging the battery beyond 80% also causes electrical problems with the forklift, such as overheated circuitry, blown fuses etc. In some cases, the charger won’t recognize the battery when recharging and you will have to repair the battery at a very expensive rate.
Always give the appropriate time to cool the battery
A suggested cooling should be observed as the battery charge temperature increases. It becomes a potential hazard if overheated; It also greatly reduces the life of the battery.
Inspect batteries, leads and plugs for damage, reporting any faults immediately
A thorough inspection of all charging devices should be conducted prior to each charge to ensure a safe and chargeable charging cycle is completed. Damaged charging equipment can lead to errors in the charging process.
Recharge only when the battery is fully charged
During the time the electrolyte discharge is absorbed into the plates, this effect is reversed while the battery is being charged. If the battery has been discharged at any stage other than fully charged you run the risk of the battery spilling acid on the next charge. The reason we charge batteries is to replace liquids that have evaporated during the charge cycle, not liquids that have been absorbed into the plates during discharge.

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Common Hydraulic System Failures in Forklifts and How to Handle Them
Here are some common failures in the hydraulic system of forklifts and the corresponding repair solutions: 1. Oil leakage: Oil leakage is a common issue in hydraulic systems. The causes can be a broken hose, poor sealing, or damaged components. To repair, identify the cause of the leakage and replace the damaged parts or repair the hose. 2. Loss of pressure: If the forklift does not have enough pressure to lift or hold loads, it may be due to a malfunctioning control valve or other issues in the system. Check and repair the control valve, inspect other components such as pumps, relief valves, and hoses to find the cause of pressure loss. 3. Inoperability: Forklifts may not operate due to various reasons, including a non-starting motor, malfunctioning control valve, or damaged components. Inspect and repair any faulty components, check power supply, and ensure all electrical connections are correct. 4. Unusual noise: If you hear strange noises from the hydraulic system, there may be issues with the pump, valve, or hoses. Inspect and repair any damaged or worn-out components and ensure all hoses are securely connected. 5. System instability: If the forklift cannot maintain its position or oscillates while lifting loads, it may be due to a malfunctioning relief valve or improperly adjusted pressure. Check and repair the relief valve, inspect pressure levels, and adjust if necessary. 6. Loss of lifting function: If the forklift cannot lift or lower loads properly, it may be due to a malfunctioning control valve or pump. Check and repair the control valve, inspect the pump and other components to determine the cause of loss of lifting function. 7. Slow response or unresponsiveness: If the forklift moves slowly or does not respond when controlled, it may be due to a stuck control valve or pump issues. Check and clean the control valve, inspect the pump and other components to resolve this issue. 8. Excessive pressure: If the pressure in the hydraulic system is too high, it can cause oil leakage or damage other components. Check and adjust the pressure in the system according to manufacturer’s instructions. 9. System vibration: If the forklift vibrates while moving or lifting loads, it may be due to worn-out or loose components. Inspect and repair any damaged components, ensuring all connections are tightened. 10. Instability during lifting: If the forklift cannot maintain its position or is unstable while lifting loads, it may be due to a malfunctioning relief valve or control valve. Check and repair the relief valve, inspect the control valve, and adjust if necessary. 11. Instability during movement: If the forklift is unstable or skids during movement, it may be due to steering system or wheel issues. Inspect and repair the steering system, check and adjust wheels to ensure safe and stable forklift movement. 12. Loss of control: If you cannot control or maneuver the forklift accurately, it may be due to a malfunctioning control system or steering component. Inspect and repair any faulty components, check and adjust the control system for optimal control ability. 13. Overheating: If the hydraulic system becomes excessively hot after a period of use, it may be due to insufficient oil flow or ineffective cooling. Check and clean oil filters, inspect and adjust oil flow to keep the hydraulic system working well without overheating. 14. Inconsistent operation: If one part of the hydraulic system operates inconsistently compared to others, it may be due to a malfunctioning control valve or damaged component. Check and repair the control valve, inspect and replace any faulty components to ensure consistency in system operation. 15. Inoperability after a period of use: If the forklift does not operate after a period of use, it may be due to worn-out components or the need for lubrication. Inspect and repair any damaged components, lubricate necessary parts to ensure the system always operates well after each use. 16. Inoperability after startup: If the forklift does not operate after startup, it may be due to weak batteries or electrical system issues. Check and recharge batteries, inspect and repair electrical components to ensure the system operates well after startup. 17. Unresponsiveness when lifting loads: If the forklift does not respond when attempting to lift a load, it may be due to a malfunctioning control valve or pump. Check and repair the control valve, inspect and replace the pump if necessary to ensure proper operation when lifting loads. 18. Inoperability after a collision: If the forklift experiences a strong collision and then does not operate, it may be due to damaged components or lost connections. Inspect and repair any damaged components, reestablish connections if necessary. By addressing these common hydraulic system failures in forklifts promptly and effectively, you can ensure smooth operations and maintain safety in your workplace.
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