Sulfation

The main reason why motive batteries fail is due to sulfation. This is a natural process where crystalised lead acid builds up on the lead plates and diminishes capacity.

Opportunity charging

The lifespan of the battery is determined by how many charge cycles it has undergone and opportunity charging can reduce a battery’s useful life by 50% – each time you charge a battery, regardless of how long, it constitutes one cycle.

Fast charging

Excessive heat generated during fast charging can destroy a battery’s active materials and reduce the lifespan significantly – fast chargers deliver a higher charging current , so unless you specifically have a fast charging battery and charger installation, it is not recommended.

Depth of discharge

Regular over-discharging — allowing a battery to drop below 20% state of charge — can damage a battery, causing premature capacity loss and shortening its lifespan.

Electrolyte

Electrolyte plays a very important role in maintaining the health of the battery. During a cycle, the electrolyte heats up and splits into its components – hydrogen and oxygen. Hydrogen gets discharged at the negative plate and oxygen at the positive plate. Over time, the water level drops and exposes the plates to air, causing permanent damage.

Faulty Cells

Faulty cells will cause the cells around them to degrade faster than normal – this can create a snowball effect when unchecked.

Operating environment

The operating environment in which batteries function can greatly affect a batteries lifespan i.e. rough terrain, hot or cold temperatures etc.

Premature “End of Life”

Due to all the critical issues mentioned above, motive batteries very rarely reach their full lifespan.

Maintenance

• But this process can be slowed down with proper maintenance.
• Leave batteries to cool after charging – the rule of thumb is 8 hours of operation, 8 hours of charge, 8 hours of rest.
• Keep the top of the battery clean – build-up from the cell breather hole during the charge process can cause tray corrosion, voltage tracking, faster self-discharge, and may even affect the electronics within the forklift.
• Keep the electrolyte levels correct – remember to top up with distilled water only when the battery is charged.
• Do not charge a battery that has only been lightly discharged – it will prematurely destroy it.
• Before disconnecting a battery from the charger, always make sure the cycle has finished.
• Check the condition of the charger’s plug and socket regularly.