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.

Power solutions will deliver the next generation of forklift efficiency. Toyota is dedicated to staying ahead of the curve in power technology innovations – testing new power sources and energy integrations that will continue to maximize the value of all Toyota Forklifts.

Lithium-ion forklift battery technology is one example of the advanced thinking driving Toyota. Lithium-ion forklift batteries provide a wide variety of efficiency advantages that can offer excellent return on investment when managed appropriately. From consistent power delivery to quicker charging capabilities, exploring lithium-ion forklift battery options can reveal your next steps in operational efficiency.

As the manufacturer of North America’s most expansive material handling product line, Toyota recognizes its responsibility in leading the charge in efficient power solutions. With almost every product in Toyota’s electric line offering lithium-ion compatibility*, you can take advantage of our industry-leading innovation now and into the future.

Key Advantages of Lithium-Ion Forklift Batteries

Lithium-ion batteries can offer your operation an advantage by increasing efficiency. If the conditions are right for the investment and the space is available for charging, there are several key factors that may lead you to adopting this energy solution.

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

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 cooldown. This can help optimize daily productivity or even reduce the number of forklifts needed to complete objectives.

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

Fewer Required Batteries: Lithium-ion forklift batteries can remain in equipment longer where one battery can take the place of three lead-acid batteries in a multi-shift use setting. This helps eliminate the cost and storage space required for additional lead-acid batteries.

Virtually Maintenance Free: Lithium-ion batteries are virtually maintenance free, requiring none of the watering, equalizing, and cleaning needed to maintain lead-acid batteries.

The Future of Lithium-Ion Forklift Battery Technology:

As the industry pushes to revolutionize, Toyota is committed to fully outfitting our electric product line with lithium-ion solutions. Toyota Material Handling was the first manufacturer to offer a UL-E and UL-EE certified integration of lithium-ion batteries and forklifts. Available on Toyota 3-Wheel Electric and 4-Wheel Electric Models, UL-certification is just the first in a long line of planned innovations.

With Toyota Material Handling, the revolution is here. 

*Only specific lithium-ion battery brands/models are compatible with specific Toyota material handling products.

Original Post: Jake Stewart, Digital Copywriter, Toyota Material Handling

Lead acid batteries are one of the most neglected pieces of equipment in material handling. Low water levels, corrosion, and electrolyte spillage are common issues that need to be monitored on a daily basis, but one practice that tends to be forgotten is the equalization charge. So, what is an equalization charge? I’m glad you asked!

What is an equalized charge on a forklift battery?

An equalization charge occurs when the battery is purposely overcharged after a full charging cycle. Essentially, you are charging the battery at a higher voltage than it is typically charged to help remove built-up sulfate and balance the voltage of each cell.

Why perform an equalized charge on a forklift battery?

If you don’t equalize your lead acid batteries, this sulfate is going to build up over time until it decreases the battery’s capacity. This buildup will effectively reduce your maximum run time, leading to more battery swaps or more time spent opportunity charging throughout the work shift. The voltage imbalance has a similar effect. Batteries work by using multiple cells that are connected in series to provide a certain voltage output. When you have varying power outputs in each cell, your overall battery voltage is reduced and your battery becomes discharged more quickly.

When should I perform an equalized charge on a forklift battery?

Equalization charges should be performed as suggested by the battery manufacturer, but many companies equalize their batteries over the weekend due to the long charging cycle. A full charge cycle is around eight hours for a standard lead acid battery and the equalization charge can be around an additional three hours. Equalization intervals will vary depending on your specific application, type and size of battery, and average operating hours.

How do I perform an equalized charge on a forklift battery?

First, you need a charger capable of equalization, as not all battery chargers have the same capabilities. Dillon Toyota Lift is here to ensure you have the proper charging equipment for all of your forklifts. Some battery chargers will automatically equalize the batteries. This capability is more common in more sophisticated systems on smaller products such as electric walkie pallet jacks. Toyota’s 8HBW23 model, for example, automatically equalizes each battery cell during normal charging.

For batteries that do require manual equalization, be sure to follow all instructions provided by both the battery and the charger manufacturer to ensure you are following the appropriate steps for proper equalization. Equalization charges typically require longer cooldowns than normal charges due to the higher amount of voltage. Allow enough time for cooldown prior to using a battery that has been recently charged.

Original Post:  Trinton Castetter, Product Marketing Specialist, Toyota Material Handling, USA

Electric forklifts are awesome! Electric forklifts are low-emission vehicles that are less maintenance than an internal combustion forklift, while maintaining a similar workload as its internal combustion counterpart. This is due to the high-powered forklift battery. With that said, electric forklifts require some unique care that other types of equipment might not require. Failing to take the proper precautions with electric equipment can lead to breakdowns that cost time and money.

1. High Temperatures’ Impact on Forklift Battery Life

Heat is a battery’s arch nemesis. Heat from forklift operation causes the lead within the industrial battery to deteriorate. If you use the forklift and battery for an entire shift, make sure you let the battery charge properly and sit long enough to cool down before using it again in the forklift. Also, while you are charging, you will want open the hood to provide proper ventilation. This will help cool the forklift’s battery. Simply, the heat can take years off the battery’s life if not appropriately managed.

2. Over AND Under Charging Damages Forklift Battery Life

Your forklift needs a good night’s rest just like the rest of us. If you don’t get enough sleep, you might be frazzled for the day, but if you over sleep, you still might still feel worn out. If you don’t charge the forklift’s battery just right, you risk harming your battery’s lifespan. If you over charge your forklift battery, you risk excess heat, causing the battery to deteriorate (heat is not your battery’s friend, as we talked about before). You do not want to under charge your battery either, because undercharging leads to plate sulphation and battery breakdown. Under charging can drastically shorten the lifespan of the battery.

3. Watering for Increased Forklift Battery Life

Is watering your battery like watering your garden? Well, kind of. Your battery requires watering to provide the appropriate discharge to power your forklift. Lead-acid batteries used in forklifts typically have a mixture of 35% lead acid and 65% water within its cells. You can see that water is very important for powering the battery. During discharge, water evaporates, but the lead acid does not. The evaporation creates disproportionate levels of water and acid. So, you need to replace that water. In this case, you need to water your battery. Easy enough right? Not quite. If the battery is topped up with water at any stage other than fully charged, you risk the battery spilling water and acid on top of the battery and onto the floor. This causes the battery oxidize and lose acid, ultimately losing capacity for operation. Simply put, you only want to water the battery after it has been fully charged.

Original Post:  Kenny Trusnik, Marketing Systems & eCommerce Specialist, Toyota Material Handling, USA