Forklift batteries can be killed (i.e., their lifespan drastically shortened) by several common issues. Here's a breakdown of the most damaging factors:
1. Overcharging
-
Cause: Leaving the charger connected after full charge or using the wrong charger.
-
Damage: Causes excessive heat, water loss, and plate corrosion, reducing battery life.
2. Undercharging
-
Cause: Not allowing a full charge cycle (e.g., opportunity charging too often).
-
Damage: Leads to sulfation of the lead plates, which reduces capacity over time.
3. Low Water Levels (for lead-acid batteries)
-
Cause: Not topping off with distilled water regularly.
-
Damage: Exposed plates will dry out and deteriorate, permanently damaging the battery.
4. Extreme Temperatures
-
Hot environments: Accelerate chemical breakdown.
-
Cold environments: Decrease performance and increase internal resistance.
5. Deep Discharges
-
Cause: Using the battery until it's below 20% charge.
-
Damage: Deep cycling frequently stresses the cells, especially in lead-acid batteries.
6. Poor Maintenance
-
Dirty battery: Causes corrosion and potential short circuits.
-
Loose connections: Lead to arcing and heat buildup.
7. Incorrect Charger Use
-
Cause: Using a charger with the wrong voltage/amperage or not matched to the battery type.
-
Damage: Either undercharges or overcharges, harming the battery chemistry.
8. Lack of Equalization Charging (for lead-acid)
-
Cause: Skipping regular equalization (typically weekly).
-
Damage: Uneven cell voltages and sulfation build-up.
9. Age & Cycle Fatigue
-
Every battery has a limited number of charge-discharge cycles.
-
Damage: Eventually the internal chemistry breaks down, even with proper care.
Post time: Jun-17-2025
