An electric vehicle depends on its battery pack as the source of energy that propels it to complete its mission. Proper care and maintenance of this pack can significantly increase its useful life and help keep the operating costs of an electric vehicle well below a traditional internal combustion engine. The following tips will serve as a guide for proper care of a Flooded Lead Acid (FLA) battery pack:

• -Batteries should be charged after each use. Avoid continuously operating batteries in a partially charged condition.
• -Distilled water should be used to replenish batteries. Particular care should be taken to avoid metallic contamination (iron).
• -Inspect battery cables to ensure they are intact and connectors are kept tight at all times.
• -Battery vent caps should be kept in place and tight during vehicle operation and battery charging.
• -For maximum battery life, batteries should not be discharged below 80% of their rated capacity.
• -If the vehicle will not be used for a period beyond a few weeks, charge the batteries, fill them and store the vehicle in a cool place that will not consistently be below 32 degrees Fahrenheit.
• -Avoid Charging at temperatures above 120 degrees Fahrenheit.
• -Only fill the batteries after charging, unless the plates are exposed. If they are exposed add water until acid covers the top of the plates by at least 1/8” and no higher than 1/4” below the top of the fill well.
• -If the charger is operating and you want to use the vehicle, unplug it from the wall before unplugging the plug at the vehicle so a spark will not be created near the batteries.
• -Wash the tops of the batteries often, to ensure batteries are clean and free of dirt or corrosion.
• -As batteries age, their performance and maintenance requirements may change. Older batteries will need to be watered more often. And, a decrease in capacity and range is to be expected.
• -Periodic battery testing is an important preventative maintenance procedure. Hydrometer readings of each cell (fully charged) gives an indication of balance and true charge level. An imbalance could mean the need for equalizing which is often a sign of improper charging or a bad cell. Voltage checks (open circuit, charged and discharged) can locate a bad battery when other methods fail. A weak battery will cause premature failure of companion batteries.

Your forklifts put in work day-in and day-out moving product and lifting and moving your business forward. The day will come when you lose time and money because the truck isn’t running as efficiently anymore. It may be difficult to pinpoint this time, but below are a few indicators that you may need a replacement forklift.

1. WEAR AND TEAR OF A FORKLIFT

Has forklift maintenance become a case of continual troubleshooting and increasing costs to keep your forklift running? If prolonged heavy use of your forklift fleet needs regular repairs, it may be time to consider replacing the equipment. When paying for continual repairs, the effect on the bottom line goes far beyond the cost of replacing worn bushings or repairing the electrical components in a drive motor. You may need a replacement forklift if you have some of the following repair needs:

• Hydraulic leaks
• Clogged fluid lines
• Worn chains
• A mast that won’t lift
• Battery problems
• Unbalanced suspension
• Steering difficulties

2. LOSING TIME, LOSING MONEY

When you experience downtime for any unit in your forklift fleet, the cost is much more than parts and labor. You also need to factor in lost productivity and the costs of idle time for operators when their equipment is being repaired. When lost profits due to delays in product movement are taken into account, the total financial impact of an older forklift can easily extend into the thousands of dollars… per hour! Keeping spare lifts on hand is not an optimal solution due to the overall increase in operating costs. Neither are quick replacements. While lower in initial costs, they can create an endless cycle of unplanned repairs that negatively impacts your business. Retiring a forklift may be necessary if this is affecting your material handling operation.

3. AVOIDING UNEXPECTED EVENTS

Poorly maintained equipment can lead to an accident or injury, which may be avoided through regular inspections and up-to-date regular maintenance. If your forklift is starting to show signs of wear and tear, it may be time to retire or replace your forklift.

If you are experiencing some or all of these scenarios with your equipment, it may be time to reach out to Dillon Toyota Lift for a conversation. We will be able to help determine if you are in need of new equipment and get you with the right forklift. If you want more information on forklift’s useful life, download our forklift management guide, “Is it Time to Upgrade Your Forklift?”

Your forklift battery is the powerhouse of your electric forklift. On average, with proper care and maintenance, a forklift battery lasts about 5 to 7 years. To safely get the most out of your forklift battery, check out the 8 recommendations below.

1. Dress appropriately for handling batteries  

Because forklift batteries are made from corrosive chemicals that can burn your eyes and skin, make sure to be dressed appropriately when handling batteries. Make sure to wear safety googles, rubber gloves, steel-toed boots, and an apron. Do not wear metallic jewelry.

2. Use the right handling equipment for moving batteries.

Forklift batteries are heavy. Smaller batteries can weigh 100-200lbs, but larger ones can weigh as much as 3,000lb. So, always use the appropriate handling equipment such as a battery lifting beam when lifting or moving batteries. Also, always make sure that the battery is properly secured before lifting or moving.

3. Handle and charge batteries in a designated area.

Having a designated area for handling and charging batteries is an OSHA-recommended best practice. When you charge your forklift battery, potentially flammable gases may be emitted. Having a designated, well-ventilated area prevents gas build-up. This designated area should also have eyewash and shower stations in the event of acid splashes and exposure.

4. Perform battery inspections and maintenance.

Batteries need to be inspected as a part of your daily OSHA-required forklift inspections. When inspecting your forklift battery, be sure to check your fluid levels. Make sure that the charging cables are intact, insulated, and connected. Look for cracks in the battery casing and for crystallization and corrosion. The battery’s contact posts should be clean.

5. Charge your batteries properly.

Properly charging your forklift battery is the best way to extend the life of your battery. A battery has a limited number of charge cycles in it, usually about 1,500 charges. Take care not to opportunity charge your battery. Flooded batteries should have 8 hours of run time, 8 hours of charge time, and 8 hours of cool-down time. If your operations require opportunity charging, see your battery supplier for the appropriate battery and charger combination for this type of charging capability.

To properly charge your battery, follow the below tips:

• • Make sure that your battery and your battery charger are compatible.
  • Be sure that the charger is off before connecting or disconnecting your battery.
  • Charge your battery when it hits 20% charge remaining. Do not charge the battery before it hits this red zone.
  • Always charge your battery completely. Partially charging your battery will count against your battery’s total number of charge cycles. Never interrupt a charging flooded type battery! (Unless you have an opportunity charger and battery combination.)
  • Avoid extreme temperatures when charging your battery. Charging and operating your battery in extreme temperatures will greatly reduce your battery’s life.
  • Allow your battery to cool down after charging. If you have a flooded or wet cell battery, you can follow the battery cycle of 8 hours charging, 8 hours cooling down, and 8 hours of working.

6. Check and maintain your battery’s fluid level.

As you use and charge your forklift battery, the fluid level of your battery decreases. That is why you should check the fluid level of your battery daily. You should add deionized or distilled water to your battery about every five to ten charges. Fill the cell with just enough water to cover the battery plate, usually about ¼” over the plate. Always add this water after charging, but never before charging. Also, do not overfill your battery because the water needs room to expand when the battery is in use.

7. Equalize your battery regularly.

Flooded, or wet cell, batteries need to be equalized on a regular basis. Over time, the water and acid in your battery become stratified. When this happens, your battery will not hold a charge well. By equalizing your battery, the electrolyte concentrate is rebalanced, and any buildup of sulfate crystals on the battery plate gets removed. Be sure to use a battery charger that has an equalizing setting.

8. Clean your battery regularly.

The top of your forklift battery needs to be cleaned regularly with battery cleaner or warm water regularly. Doing so is not only good maintenance practice; it can also help you maintain your battery’s manufacturer’s warranty. Also, cleaning can help you avoid battery build-up which can lead to tray corrosion and faster self-discharge.

Taking care of your forklift battery is greatly beneficial for your forklift and for your business’s bottom line. View original post HERE

When contemplating a forklift fleet transition from lead acid batteries to lithium-ion, there are wide variety of factors that need to be considered including fleet size, shift number, and your operational environment. In the right setting, it’s a big investment that comes with a big return when managed properly — including a wide variety of efficiency advantages.

At the same time, as you might expect, a different power source will come with a wide variety of changes to your operational practice. Here are a few of the differences you can expect, as well as some tips to help make the transition as smooth as possible for your fleet.

1. More Consistent Power

Whether you have a single-forklift operation or a large fleet working 24-hours a day, one important factor in delivering results is consistent power throughout the charge of the battery. Lithium-ion forklift batteries deliver consistent power and battery voltage throughout the full charge, whereas lead-acid battery charges deliver declining power rates as the shift wears on.

Bottom line: You won’t experience a lag toward the end of the lithium-ion battery’s charge, so plan your tac times and work flows accordingly.

2. End of Life

Because lead-acid batteries have been around for so long, there are many recycling programs in place for them when they reach the end of their lives. The recycling rate on lead-acid batteries is high. Recycling programs for lithium-ion batteries are still being developed.

Bottom line: Do your research and plan in advance for the end of your lithium-ion battery’s life so you know how to handle and dispose of the old battery appropriately.

3. Faster Charging Speeds

In the context of day-to-day operations, lithium-ion forklift batteries offer significantly faster charging speeds and don’t require charging cool down. This can help optimize daily productivity or even reduce the number of forklifts needed to complete objectives.

Bottom line: Be prepared with additional work to keep operators and their equipment busy — you may start moving faster than anticipated.

4. Opportunity Charging

Lithium-ion forklift batteries can be opportunity charged in any setting, eliminating the need for time-consuming battery swaps.

Bottom line: Make your charging stations convenient to your operators so that they can take advantage of this option during breaks, lunch, and other windows of free time.

5. Fewer Batteries Required

Lithium-ion forklift batteries can remain in equipment longer — to the point where one lithium-ion battery can take the place of three lead-acid batteries in a multi-shift use setting. This helps reduce the cost of storage space required for additional lead-acid batteries.

Bottom line: Figure out how much storage space you’ll actually need with the new set up, consolidate your storage space accordingly, and make use of the “leftover” space with value-adding tasks.

6. Cost

The reality is, lithium-ion batteries do cost more than lead-acid batteries. As a result, despite the operational efficiencies they provide, they are not necessarily the right solution for every operation.

Bottom line: Before transitioning, be sure that the efficiency returns you expect will outweigh the upfront cost.

7. Virtually Maintenance Free

Lithium-ion batteries require none of the watering, equalizing, and cleaning needed to maintain lead-acid batteries. This is a money savings in terms of both maintenance costs and downtime.

Bottom line: Make a plan to use the time you get back from this necessary maintenance for other productive tasks.

8. Culture Change

Forklift operators who are used to using lead-acid batteries will have to change the way they do their jobs when transitioning to lithium-ion because of the need to plug the forklift in to charge every time it is not in use. This transition requires a culture change that usually includes time for a learning curve.

Bottom line: Communicate clearly and intentionally before, during, and after the transition with your operators — and give them the time they need to adjust to a new way of powering their equipment.

Original Post: Justin Albers, Corporate Communications Specialist, Toyota Material Handling

The proper maintenance and handling of forklift batteries is imperative to their longevity. There’s a right way and a wrong way to maintain and handle forklift batteries and doing it properly will ensure your investment is maximized.

Proper Handling

Forklift batteries can be heavy and dangerous if not handled properly, so it’s important to be educated on the correct way to handle them. Use these tips for some ideas about handling batteries properly:

1. • Use special equipment, like a walkie pallet jack equipped with a transfer carriage, to maneuver the battery. Because of the weight of some forklift batteries, no single person should attempt to move a forklift battery alone. Steel toe shoes should also be worn while moving the batteries.

• • An eye and hand washing station should be nearby. Should any hazardous liquid come in contact with hands or eyes, a hand and eye washing station should be conveniently located nearby to remove it as quickly as possible.

• • Chemical-resistant protective gear should be worn while maneuvering batteries. Having a conveniently located eye and hand washing station is necessary, but chemical-resistant gear should also be worn to keep the need for the station at bay. This includes safety glasses and gloves.

1. • Remove all metallic jewelry when handling and charging.

Proper Charging

Properly charging a battery is all about doing it at the right time, for the right amount of time. Use these tips when charging your forklift battery:

1. • Designate an area specifically for battery charging. This is an OSHA-recommended best practice.

• • Remember that lead acid batteries should be charged at 80 percent depth of discharge. Charging prior to 80 percent can result in reduced battery life depending on the type of battery.  Discharging the battery past 80 percent depth of discharge can also be detrimental.

• • If your battery overflows, take time to rinse it. Rinsing your battery after an overflow will help prevent corrosion.

• • Ensure compatibility between the battery and the charger. The charger that is being used should match the voltage/amperage of the battery. Color coding the connectors and clearly labeling the chargers can help to prevent accidentally connecting a battery to the wrong charger. Proper training is also imperative.

• • Avoid overcharging the battery. Some batteries have battery management systems that can prevent overcharging. If yours doesn’t, take precautions not to overcharge it, which can reduce the battery’s life.

• • Charge and operate the batteries at the proper temperature. Charging a battery in extreme cold or heat can cause reduced service life. Since battery types and specifications may vary, contact the battery manufacturer for their recommended charging temperature range.

• • Add water when needed after the charging cycle. Adding water to a wet-cell battery prior to charging the battery is a common mistake. Pure or distilled water should be used and the watering should occur after a full charge cycle to bring the electrolytes to the proper level.

• • Ensure the charger is turned off before connecting or disconnecting the battery.

These maintenance tips will help you keep your Columbia fleet in service safely and effectively.

1. Perform a thorough inspection of all wiring harnesses with particular attention to evidence of rodent habitation. If evidence is found, it may be necessary to remove vehicle components for a more detailed inspection. Rodent damage to wire harnesses can cause severe failures.
2. Inspect electrical connections for corrosion and clean, as necessary.
3. Operate the brakes and monitor for correct performance. After operating, ensure the pedal returns to its correct ready position.
4. Operate the throttle and monitor for correct performance. After operating, ensure it returns to the correct ready position.
5. Measure battery pack voltage. Extremely low voltages may require independent charging before the vehicle charger will charge the battery pack. Extreme low voltages will fall in these ranges: 5.3V and lower for 6V batteries, 7.2V and lower for 8V Batteries, 10.3V and lower on 12V batteries.

These simple tips will help ensure your vehicle is ready for the toughest conditions. If you find any damage during these inspections, make sure to contact us and we can provide the parts and service that may be needed to get your vehicles back to peak performance.

To view the complete line of Columbia Utility Vehicles, click here!

BYD’s new forklift charger sets a high bar for the industry. Thanks to the device, BYD forklifts can be fully powered using a 110V charger that requires no extra wiring and can be connected to a standard wall plug.

BYD forklifts can fully charge in under 90 minutes and can run 10 hours per day, seven days a week. The reliable batteries in BYD forklifts require zero maintenance and come with a 10 year warranty.

Every business owner wants to increase productivity. Here are six easy ways to get more from your forklift.

1. Request a service inspection be conducted regularly. See if a maintenance plan is right for you or help train and back up your in-house technicians.
2. Leave promptly and don’t idle. Don’t start the engine until you’re ready to go to avoid wasting fuel and turn off the engine if it looks like you could be waiting for more than a minute.
3. Don’t make sudden changes in speed. Maintain a steady pace, drive smoothly and accelerate gently. It will save fuel and reduce maintenance costs.
4. Train your drivers. Good training not only helps improve safety, but also trains your operators to approach a load correctly to avoid unnecessary maneuvering and make them more efficient.
5. Keep up-to-date with maintenance. This is extremely important to keep your forklift fuel efficient and running well.
6. Buy the right tires and check them often. If your forklift has pneumatic tires, make sure they are inflated correctly. Under-inflated tires increase fuel consumption and wear more quickly. If your application is primarily indoors on concrete, cushion tires are a better bet.

BYD is an innovator in the marketplace. Trusted and reliable, BYD (Build Your Dreams), the world’s premier manufacturer of batteries, celebrates #BatteryDay today and every day.

Founded in 1995 as a pioneer in battery technology, BYD’s mission is to change the world by creating a complete, clean-energy ecosystem that reduces the world’s reliance on petroleum. BYD’s innovative products are leaders in multiple sectors, including battery-electric automobiles, buses, medium- and heavy-duty trucks and forklifts; the SkyRail monorail system; solar power generation and energy storage systems; and consumer electronics.

BYD always aims to make battery safety its key indicator of quality. BYD puts its batteries through rigorous safety tests, from burning, to overheating, dropping, perforation, crushing, and even shooting nails through their casings. Throughout these tests, BYD batteries have proven extremely safe, never overheating or exploding.

BYD forklifts can fully charge in under 90 minutes and can run 10 hours per day, seven days a week. The reliable batteries in BYD forklifts require zero maintenance and come with a 10 year warranty. 

BYD’s new forklift charger also sets a high bar for the industry. Thanks to the device, BYD forklifts can be fully powered using a 110V charger that requires no extra wiring and can be connected to a standard wall plug.

View BYD Forklifts