When operated correctly, electric forklifts handle heavy loads safely. Read the truck’s data plate for information such as its weight and load capacity. Learn how to read and understand an electric forklift data plate.
Proper maintenance protects forklift batteries and ensures you get the most use out of your equipment. Taking care of the battery improves its performance and saves your business money. Use these four tips to get the most out of your forklift battery.
Only charge your battery once it is depleted to 20–30 percent of its charge capacity. If you charge before it reaches 30 percent, you will shorten the battery’s lifespan. And using the battery after it has less than 20 percent charge will increase wear on the unit.
Completely charging a lead-acid battery takes about eight hours. After charging, let your battery cool for the manufacturer’s recommended amount of time before use—typically another eight hours.
Add Water As Needed
Maintaining the electrolyte level is key for getting the most out of your forklift battery. Typically, batteries require deionized water, but you should follow your manufacturer’s instructions to be sure. Watering will keep the electrolyte at the right acid-to-water ratio.
Only water the battery at the end of the charge cycle. Watering before or during the charge cycle increases the chance of a boil-over, pushing hazardous sulfuric acid outside the battery.
Store in Safe Conditions
Proper battery storage protects the equipment’s working lifespan. Prevent sulfation by fully charging the battery and adding water before storage. Store in a dry location and ensure air can circulate around the battery. Protect the top of the battery from dust and debris.
Generally, you should store forklift batteries at temperatures between 60 and 80 degrees Fahrenheit. Do not place batteries near sources of heat, such as radiators.
Recondition the Battery
Finally, forklift batteries have an average lifespan of about five years or 1,500 charge cycles. Workloads and battery maintenance affect how long your battery will operate. Fortunately, once your battery reaches the end of its initial lifecycle, you can have it professionally reconditioned to give it a second life.
At Green Power Forklift Batteries, we use an 18-stage reconditioning process to maximize the functional lifespan of batteries and ensure high performance. Contact us for more information on how refurbished forklift batteries can benefit your business.
Material handling efficiency improves customer satisfaction, lowers overhead expenses, and increases revenue. Read to learn effective ways to improve your material handling efficiency.
Minimize and Improve Manual Handling
Manual handling is when workers move and handle products by lifting, holding, carrying, pulling, and pushing. Risk factors of manual material handling include forceful exertion, high repetition, and sustained awkward postures that put stress on joints and muscles. When possible, handle materials with machines rather than manually to reduce worker risk.
Give workers adequate breaks throughout the day to reduce fatigue. Workers should use the right form when lifting and moving packages and avoid bending and twisting when they lift.
Improve the Warehouse Layout
Improving the warehouse layout will help optimize workflow. The better organized your warehouse, the more efficiently workers can move.
You will need to use different techniques to optimize individual areas of your warehouse. For example, you should maximize your use of vertical space for storage. But you can improve the use of the staging area by receiving goods during one shift and shipping them during another.
Another effective way to improve material handling efficiency is to maintain equipment. Schedule maintenance to minimize disruptions to your routine. A maintenance schedule will ensure you promptly inspect, adjust, and repair equipment.
Docking, storing, lifting, and packing equipment make it safer and easier to handle materials. Maintaining equipment throughout your facility extends your machines’ life spans and helps prevent the need for expensive repairs.
Assess workflows throughout your facility to find opportunities to optimize workflows. You might discover simple changes make a big difference. For example, opportunity charging forklift batteries during natural breaks in the operator’s shift can save time on charging and changing out the battery.
Get the most work out of your lift equipment with batteries from Green Power Forklift Batteries. We carry a range of industrial brands, including Toyota forklift batteries. Shop with us today for new and refurbished batteries.
A supply chain management plan coordinates processes to optimize the shipping and delivery of goods and services. Creating a plan with green initiatives in mind helps lower energy usage and minimize waste in supply chains. Discover a few key tips for creating a green supply chain management plan.
Minimize the Use of Raw Materials
Supply chain systems connect producers, transportation companies, warehouses, distribution centers, and retailers. People at every step of the supply chain should re-examine their practices to ensure they don’t over-rely on raw materials.
Producers can evaluate how new technologies and innovations can improve their manufacturing processes. Redesigning a product to include fewer components or use recycled materials can help preserve natural resources.
Another key tip for creating a green supply chain management plan is to optimize transportation. Strategies for eco-friendly shipping focus on lightening the weight of goods and moving products on efficient routes. As electric vehicles grow more popular, hybrid and electric delivery fleets become more attractive.
Additionally, a route-planning system helps save time and fuel on deliveries. Software that automatically informs drivers of road closures, traffic issues, and the best routes to use in real time makes trips more efficient.
Reuse and Recycle Materials
Finally, reusing and recycling materials ensures you extract the full value of items before throwing them out. Supply chain members, from producers to retailers, can reuse materials and recycle.
One way that warehouses and distribution centers have improved their sustainability efforts is by replacing internal combustion (IC) forklifts with electric forklifts. Managers can further enhance sustainability by using refurbished forklift batteries.
Refurbished forklift batteries retain high charge capacity but cost a fraction of the price of new forklift batteries. At Green Power Forklift Batteries, our refurbished batteries have a minimum of 85 percent of the rated capacity of new batteries. Check out our selection of reconditioned forklift batteries for sale for a cost-effective way to improve your business’s sustainability.
Electric forklifts have lower operating costs than forklifts with internal combustion engines. They’re also more energy efficient, which makes them eco-friendlier. Create a properly functioning charging area and keep workers safe with these tips for setting up a forklift battery charging station.
Meet OSHA Requirements
OSHA outlines safety standards for creating a lead-acid battery charging station because the charging process can create hazards. The risks associated with charging are exposure to corrosive chemicals, electrolyte boil-over, mismatched voltage, electric shock, excessive heating, and fumes. Refer to OSHA standard 1910.178(g) to create a safe charging station.
The charging station will need facilities for flushing and neutralizing spilled electrolyte and for fire protection. The flooring material should resist acid damage. Place bollards or barriers around chargers to protect them from being damaged by lift trucks. The room needs adequate ventilation for dispersing fumes from gassing batteries.
Train employees on proper lift truck management, how to use battery-handling equipment, and safety precautions to follow. Post signs throughout the space reminding personnel of hazards and precautions.
Ensure Adequate Space and Electrical Service
The next tip for setting up a forklift battery charging station is to choose an area that has adequate electrical service and space. Calculate power requirements based on your lift trucks’ needs and ventilation and cooling equipment.
Consider the size and number of lift trucks that will enter the charging station and the floor space you need for battery storage. You can invest in a vertical storage system to save floor space. Don’t forget to leave enough square footage for future growth, which will require more batteries and more electric lift trucks.
Install Chargers and Battery Changing Equipment
Mount all four corners of each charger on a shelf. If you are stacking the chargers, follow the manufacturer’s instructions to ensure adequate ventilation.
The DC cable leads should connect to the battery without going over the manufacturer’s recommended cable lead length. Personnel should have easy access to chargers for maintenance.
Depending on your lift trucks, you’ll need equipment for overhead or side extraction. Overhead battery extractors use a fork attachment and lifting beam that lifts batteries vertically from the truck.
For a smaller fleet with just one or two trucks, you can use a portable gantry crane. For larger fleets, a track-mounted crane works better.
Side extraction equipment usually uses a vacuum or magnetic arm to remove the battery. Equipment such as walkie transfer carriages and battery transfer carriages keep the battery at a constant height during extraction and replacement.
Improve your fleet’s energy efficiency with electric forklifts. Green Power Forklift Batteries has new and refurbished industrial forklift batteries for sale. Shop for the best lead-acid forklift batteries today.
A small amount of battery sulfation is a normal process for lead-acid batteries. But when the buildup of lead sulfate crystals becomes excessive, it reduces the battery’s performance and can cause it to fail. Read on to learn more about forklift battery sulfation causes and prevention.
What Is Battery Sulfation?
A lead-acid battery has lead plates and lead dioxide plates. The plates are in an electrolyte solution of sulfuric acid diluted in water.
When batteries discharge, the lead active material on the plates reacts with the electrolyte. This reaction creates lead sulfate residue on the plates.
During normal use, the lead sulfate residue is only temporary. Sulfation will disperse during recharging. But when large lead sulfate crystals become permanent, they damage the battery.
What Causes Sulfation?
Knowing the causes of forklift battery sulfation can help you prevent the problem. Sulfation happens as a normal result of the battery’s chemical processes. But the following factors can increase the rate or amount of sulfation to a harmful degree:
- Leaving the battery undercharged
- Storing the battery at high temperatures
- Not charging and discharging the battery for a prolonged period
- Storing the battery without a full charge
Practice good battery care and maintenance to avoid these common causes of battery sulfation. For example, if you need to store a battery, fully charge it and place it in a temperature-controlled space.
Soft vs. Hard Sulfation
If your battery takes longer to charge or needs to charge more often, you might have a sulfated battery. The buildup can also cause excessive heat and complete battery failure.
There are two types of sulfation. Soft sulfation, otherwise known as reversible sulfation, and hard sulfation, also called permanent sulfation, which is irreversible.
If you recognize sulfation early enough, an experienced professional can sometimes reverse it. One indication of soft sulfation is when a fully charged battery can hold a stable voltage on discharge. But if the voltage drops rapidly, the battery likely has hard sulfation.
If you see signs of sulfation, contact Green Power Forklift Batteries. As a premier forklift battery dealer, we thoroughly inspect and recondition batteries. If your battery has permanent sulfation, we have new and refurbished batteries to keep your business running. Contact us today.
Refurbished forklift batteries can benefit your business in many ways. To determine whether this option is right for you, consider what you should know before buying a reconditioned forklift battery.
It’s always important to buy from a trustworthy forklift battery company. When you shop with an experienced company with a strong reputation, you purchase a reliable product.
Green Power Forklift Batteries reconditions batteries through testing, charging, performing desulfation, and cleaning. We complete our 18-step process in multiple stages: the initial inspection, diagnosis, equalization, capacity maximization, and finishing. Thorough refurbishment results in a clean battery that retains a minimum of 85 percent of the rated capacity of a brand-new battery.
They Will Save You Money
Another thing to know when you consider buying a reconditioned forklift battery is that this product saves your business money. The cost difference between a new and refurbished lead-acid battery is significant.
Of course, your business wants to balance cost and quality. The upfront cost of a refurbished battery is much lower than the cost of a new one. Also, when the refurbished battery retains a high percentage of its original, new-condition capacity, that’s a true deal. For many businesses, buying a reconditioned battery makes the most financial sense.
They’re More Eco-Friendly
Industrial business owners and managers should look for ways to improve their ecological impact. One of the best ways to do this is to use eco-friendly power alternatives. Not only are reconditioned forklift batteries reliable and cost-effective, but they’re also eco-friendlier than new batteries.
By buying a reconditioned battery, you make the most of the labor and materials it took to make the battery. And when you use a reconditioned battery, you reduce the pollution created by manufacturing new batteries. Ultimately, buying reconditioned uses resources in the best way.
Find the right reconditioned forklift battery for your lift truck at Green Power Forklift Batteries. Save money and make your business more environmentally friendly with a reliable refurbished battery. Give us a call or search our refurbished battery list today.
Forklift operators deliver, move, load, and unload materials in warehouses, construction sites, and other industrial places. While forklifts make moving and lifting large and heavy objects easier, operators must follow best practices to stay safe and work efficiently. Read here to find out the do’s and don’ts of forklift operators.
Do: Inspect and Maintain the Forklift
A thorough pre-shift inspection protects operators and other workers and minimizes the likelihood of damaging goods. Inspections also optimize the forklift’s performance.
This OSHA-mandated task typically takes less than 15 minutes. Use your company’s inspection checklist to assess components like tires, chains, the battery, and the fork.
Don’t: Overload the Forklift
The load weight, distribution, dimensions, and position affect the forklift’s stability and ability to carry. The stated capacity assumes the load is a cube with an evenly distributed weight, with the center aligned with the standard load center. Irregularly shaped loads, unbalanced weight distribution, and an uncentered load can reduce the carrying capacity.
Do: Drive Responsibly
For everyone’s safety, drive responsibly. While you had to learn this to earn certification, growing accustomed to driving can lull you into dropping your guard.
Only drive on designated roadways at your workplace. Avoid uneven or slick surfaces. Never drive with the load raised in the air.
Drive with your seat belt fastened. Use the horn to alert pedestrians and other operators when rounding a corner. Slow down when turning corners, and always maintain a safe distance from others.
Don’t: Leave the Forklift Unattended
Never leave the forklift unattended. According to OSHA, a forklift is unattended if either of the following is true:
- The forklift is not in the operator’s view
- The forklift is in the operator’s view, but the operator is 25 feet or further away from the truck
If you need to leave the forklift, park it in the designated location. The parking location should not block walking pathways or exits and entrances. Take the keys with you to prevent unauthorized use.
This list of do’s and don’ts shows the necessity of forklift operator training. Operators can prevent disaster by inspecting and maintaining the forklift components, correctly loading the forks, driving responsibly, and parking properly.
Equip your business’s lift trucks with new forklift batteries from Green Power Forklift Batteries. Our industrial batteries range from 12 to 80 volts and power a variety of forklift types. Get a quote from us today!
Periodically cooling off your forklift battery makes it safe and effective for powering your lift truck. If your battery overheats, it could spell trouble. Read to find out the five signs your forklift battery is overheating.
1. You Feel Heat Emitting From the Battery
The most obvious way to tell the battery is overheated is to feel the heat coming off it. When charging and discharging, it’s normal for the battery to get hotter because of the chemical reaction going on.
Manage the temperature by properly charging the battery and keeping the environment cool. In general, you should discharge the battery for eight hours, charge it for eight hours, and let it rest for eight hours. Follow your manufacturer’s instructions.
2. Hot Cables and Connectors
While it’s normal for batteries to heat up during use or while charging, the battery’s cables and connectors should not get hot. Weak contact points at the ends of the connectors can cause overheating. Replace overheating cables and connectors before they melt their insulating outer sheath.
The sulfuric battery acid in an overheated battery can burn through the cable’s insulation and corrode the copper wiring. If this happens, you will see swollen cables. Replace corroded, swollen, and damaged cables and connectors.
3. The Truck Has Intermittent Power Loss
An overheated battery can cause power to your lift truck to cycle on and off. The forklift might sputter or backfire. If you experience this, immediately stop using the forklift. Check the battery as well as the alternator, broken wires, fuel filter, and vacuum hoses.
4. The Forklift Won’t Start
Another sign that you may have an overheated battery is that your forklift won’t start. High temperatures in the battery will heat the electrolyte solution and weaken or ruin the battery.
You can check the voltage of the fully charged battery. If the voltage doesn’t have a full charge after a charging cycle, then it is probably time to replace it.
5. Warning Light
If you see a warning light appear on your lift truck display, don’t ignore it. The light can signal issues with the engine, battery, or fuel tank.
Make sure to schedule ample cooling time for your batteries and keep them properly watered. The forklift battery should operate below 113 degrees Fahrenheit or 45 degrees Celsius.
If you need to replace your faulty battery, shop for electric forklift batteries from Green Power Batteries. Whether you choose new or refurbished, you can rely on these batteries to keep your lift trucks going. Shop with us today.
If you’re not performing regular equalization charges on your forklift battery, you could be damaging your equipment. Read on to discover what forklift battery equalization is and why it’s important.
Equalization: Intentional and Beneficial Overcharging
An equalization charge is an intentional overcharging of your lead-acid battery. Follow your battery manufacturer’s instructions regarding how often you should perform equalization charges. The equalization charge can take an additional 3 to 15 hours, depending on your battery, so keep this requirement in mind when planning your work schedule.
Routine charging practices impact how effectively forklift batteries power equipment; charging also affects the length of the battery’s working life. Get the best and safest battery performance by utilizing equalization charges.
Maintain Equal Optimal Voltage Capacity Across the Cells
It’s important to perform an equalization charge on your lead-acid battery to equalize the voltage across all cells. Each battery cell has a nominal voltage of 2 volts, but the actual voltage can vary, and the voltage in the cells is not perfectly balanced.
As you use the battery over time, the difference in voltages between cells will grow. For the best discharge performance, you want to maintain a low voltage difference and increase consistency between cells. By overcharging with an equalization charge, you can bring each cell back to its optimal voltage capacity and improve battery performance.
Equalize To Break Down Sulfate
Finally, an equalization charge is critical because it breaks down sulfate. The sulfation process happens when the sulfuric acid in the battery’s electrolyte breaks down and releases sulfur ions. The free sulfur ion crystals build up on the battery’s lead-acid plates. Without intervention, the crystals will grow, harden, and completely cover the lead plates.
An equalization charge overcharges the battery at a low, controlled rate. The process slightly heats the electrolyte, forces current through the plates, and removes light sulfation. Heavy sulfation will require other forms of intervention, but regularly equalizing the battery can keep sulfation at bay.
Now that you know more about forklift battery equalization and why it’s important for routine maintenance, turn to Green Power Forklift Batteries as your preferred forklift battery supplier. We carry new and reconditioned batteries for a variety of industrial applications. Request a quote on lead-acid or lithium-ion batteries for your business today.