forklift battery Archives

Forklift Battery Troubleshooting

Forklift Battery Troubleshooting: If only they could last forever.

Chances are your battery is going to give you problems at some point in time. When those problems arise, we want to you to be prepared which is why we made this forklift battery troubleshooting guide. Below is a list of common problems associated with forklift batteries that occur over time. Listed are the different battery troubles, the conditions what come with them, what’s causing the problem, and how to collectively act upon it.

 

forklift battery troubleshooting intella liftparts

Short Circuited

Condition:

  • Very low cell voltage and specific gravity during recharging and discharging
  • Low gassing while charging
  • Extreme rise of electrolyte temperature during charging phase
  • Fast drop of gravity after charging

 

Why is this happening? Probable cause:

  • Short circuited due to a dropping of active materials
  • Short circuited due to a broken separator
  • Short circuited due to advancing of broken pieces during manufacturing of battery

 

Where to go from here:

  • Replace the faulty cell with a single charged cell

 

 

Sulfation

Condition:

  • While charging, the voltage and electrolyte temperature are much higher than the standard
  • Gassing is accelerated from charging and the gravity does not rise to normal
  • Voltage drops quickly while discharging
  • In some extreme cases, plates may become whitened

 

Why is this happening? Probable cause:

  • Repeatedly overcharging and discharging of battery
  • Plates exposed to open air for extended period of time
  • Lack of care during storage process
  • Excessively high gravity while using battery
  • Impurities causing excessive self discharge of battery

 

Where to go from here:

  • If the battery is in rather early conditions, remove the probable cause
  • Replace the faulty cell with a single charged cell if damage can’t be fixed

 

 

Excessive Self Discharging

Condition:

  • Quick drop in gravity after charging
  • Charging capacity of battery significantly reduced

 

Why is this happening? Probable cause:

  • Using impure water in the battery
  • Specific gravity higher than it should be
  • Excessively high temperature of electrolytes
  • Battery container has been insufficiently cleaned

 

Where to go from here:

  • Take daily care of the battery
  • Replace the faulty cell with a single charged cell

 

 

Exchange of Polarity

Condition:

  • Polarity switched around in some cells during discharging or high temperature of electrolytes
  • Electrolytes dissolve causing an emission of gas that changes the polarity of the battery

 

Why is this happening? Probable cause:

  • Caused by quick discharge without noticing a low capacity in a cell
  • Ill preparation of certain means like an equation charge

 

Where to go from here:

  • Replace faulty cell
  • Take daily care of the battery

 

Forklift Battery Troubleshooting Intella Liftparts

Other Possible Factors

1. Color of electrolyte has changed to brown

– Due to corrosion of positive plate mixing into electrolytes

– Check voltage and gravity of battery

– Replace electrolyte

 

2. Chlorine smell during charging

– Due to sea water mixing into electrolytes

– Replace electrolyte and charge the battery until the smell is gone

– Replace cells

 

3. Electrolyte excessively reduced

– Battery cells are cracked

– High electrolyte temperature while charging

– Find causes and follow repair procedures

 

4. Unnaturally high electrolyte temperature

– Due to lack of electrolytes

– Due to shorted cells and/or reversed polarity

– Solder battery

 

5. Heat from connector portion

– Bad connector contact

 

Forklift Battery Troubleshooting Intella Liftparts

 


 

 

Need forklift parts?  With thousands of parts in stock, quick shipping and great customer service, Intella Liftparts can help. You can also check out our YouTube channel here for how-to videos, product overviews, and other great clips.

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My Forklift Battery Smells Funny

My forklift battery smells a lot like rotten eggs – Why?

We hate to be the bearer of bad news but the smell of rotten eggs Forklift Battery Charger Intella Liftparts
coming from your forklift battery is not a good thing. The unpleasant smell resembling that of expired eggs is actually sulfur. Forklift batteries are made from lead plates that are covered in a lead oxide paste. This then sits in a pool of sulfuric acid. Almost every vehicular battery, regardless of the application, will at some point get a bad cell. When one of these battery cells stop taking a charge, the battery charger will throw everything it’s got at it to try and bring up the voltage. This causes the cell to get very hot and will boil the sulfuric acid stored inside the battery. When sulfuric acid gets cooked, you’re left with the rotten egg smell. Now if you’ve got an internal combustion forklift, the alternator could be overcharging your battery also resulting in the funky smell.

 

Forklift Battery Chargers Intella LiftpartsSo now I know why it smells, but what do I do now?

First thing’s first: Turn that charger off and let the battery cool down. No one likes boiling sulfuric acid. For safety reasons, place a tag on the battery to make sure no one uses it. Get in contact with a professional to check out your battery and charger. Have the professional replace the bad cell. If you can’t replace the cell, replace the battery. Following the replacement of the battery or the battery cell, check to see if your charger is working properly. No one wants to buy a new battery only to have it ruined by a bad battery charger.

What caused my battery to fail?

Assuming that it wasn’t your battery charger that was the problem, there are a few things that may have caused your battery to fail.

  • Water – If the water that you add to the battery is full of dissolved minerals, the minerals can accumulate making it rather difficult for the battery to take a charge. This can cause the cell to overheat.
  • Warehouse Floor – Working on an uneven floor can jar the forklift battery, knocking the oxide paste off of the plates causing them to short out.
  • Manufacturer’s Defect – Every now and then a battery may flat out under-perform. This can be due to a defect in the battery. Check with the manufacturer of the battery in regards to warranty information as many times they will be covered for a certain number of years.

 

 

Where to go from here.Forklift Battery Charger Intella Liftparts

Thinking your forklift battery charger is the problem?

Here are some helpful links:

Guide to selecting a new battery charger

Battery charger catalog


 

Need forklift parts?  With thousands of parts in stock, quick shipping and great customer service, Intella Liftparts can help. You can also check out our YouTube channel here for how-to videos, product overviews, and other great clips.

Intella Liftparts

Post by Intella Liftparts