The occupational safety and health administration osha standard, 29 cfr 1910. Stick to protocol when it comes to forklift battery maintenance and charging your lift trucks. Forklift battery charger 10 charging tips for lift truck batteries. Emerging technologies fact sheet efficient forklift. Risktopics incidental hazards battery charging of vehicles including lift trucks august 2015.
Pdf evaluation of different forklift battery systems using. The starting charge amps and length of time required for a charge vary depending on the charger model. Get a copy of the information on this page as a single pdf document that makes saving, printing, and sharing this. Forklift batteries are a critical business investment.
Persons performing battery inspections should follow all of the requirements. You must boost charge a weak battery before load testing. These days battery powered industrial forklifts are becoming increasingly popular due to their ability to be used in a variety of applications and industries. If the polarity is reversed, the dc fuse will blow.
However, a consistent need for watering may be a sign that something is wrong with your battery or charger. Forklift battery charging methods the discovery process. The most common power sources, battery and lpgpropane, are specifically regulated by calosha standards. Follow proper lockouttagout procedures 29 cfr 1910. The charger must be grounded to the ac system ground for personnel safety. It is important to perform forklift battery inspections before a forklift is used and before and after the battery is charged. Under normal circumstances, we recommend charging a forklift battery when it approx.
Battery charging areas should be provided with systems for flushing and neutralizing spilled electrolyte, fire protection, protecting charging apparatus from damage by forklifts, and adequate ventilation of fumes from off gassing hydrogen gas from the batteries. This course discusses multiple types of batteries and the theory of battery charging. Forklift battery use and maintenance osha safety manuals. Charging forklift batteries requires training and caution due to the batteries weight, the corrosive sulfuric acid contained within, the possibility of explosive hydrogen fumes, and the chance of electric shocks on unprotected exposure. If possible, the instructor should select a video that uses a setting similar to the workplace.
Distilled water is not required however in areas where hard water exists, distilled water or bottled water may be the most economical option. Such as battery, cables, and other components in the alternator circuit. Charging a battery whenever it is convenient is not the best way to go, it should only be charged at certain times and to certain degrees. Toyota forklift battery charger maintenance program. The discharged battery is removed from the forklift and a charged battery is installed in its place. What is forklift battery gassing and how do you manage it.
Get a copy of the information on this page as a single pdf document that makes saving, printing, and sharing this information very convenient. Make sure the charger is properly sized matched to the battery it is charging. Forklift battery charger 10 charging tips for lift truck. These records will be invaluable when it comes to predicting when battery replacement is going to be necessary. A battery manufacturer will want to see watering records if a warranty claim is needed. The battery case houses the batterys individual cells. Make your battery last is a two part series to educate you on the basics of forklift battery maintenance. If your battery is smelling like rotten eggs, it is best to pull it from service immediately and have a professional test the battery and recommend next steps. Forklifts, battery charging and material handling page 2 battery charging forklift power sources also may pose hazards to employees. Ongoing battery maintenance is critical so that the forklift is always safe and ready to get your work done. In trading and industrial activities, electric powered vehicles such as fork lift.
Forklift battery charging safety be certified today. The green eye only allows you to look at one cell in the battery and as such i t li bl i di ti f ll b tt diti th t i h th h is not a reliable indication of overall battery condition. Remove all metallic jewelry when handling and charging. Forklift battery repairs happen, but it is our goal to keep that to a minimum. If youre not sure how your ventilation system stacks up. You should charge a forklifts battery only when it dips below 30% to preserve your plates. Forklift battery care instructions fleetman consulting inc. Forklift battery maintenance guide bhs bhs industrial equipment. Chargers and charging equipment for electric road vehicles are not covered. Forklift operators handbook a guide to safe operation.
And if your forklift batteries fail, business stops. Linde electric forklift trucks boast an intelligent energy management system that ensures that the trucks are able to draw optimal driving performance and longlasting durability from their drive batteries. Although a battery is called a 12 volt battery, its voltage varies from about 12. Electric forklifts, battery charging and changing procedures. All new powered industrial trucks acquired and used by an employer shall meet the design and construction requirements for powered industrial trucks established in the american national standard for powered industrial trucks, part ii, ansi b56. A forklift is a vehicle similar to a small truck that has two metal forks on the front used to lift cargo.
Watering instructions 1 use clean water that has a low mineral content. Top 10 tips on how to charge a forklift battery with with an industrial lift truck charger. Installation and operation manual forklift battery chargers. Although it may seem easy to charge a battery when it is convenient, proper maintenance requires battery charging at certain times to certain degrees. Lpgpropane tank and refueling safety requirements are presented in a separate hazard prevention data sheet.
Over or undercharging industrial batteries can significantly decrease its. Dont allow your forklift batteries or forklift battery chargers to drag down the rewards that properly maintained equipment. The transformer output is connected to a fullwave bridge of silicon diodes, which provides dc charging current to the battery. The battery charge gauge indicates overdischarging.
The discharged battery is removed from the forklift and a charged battery is. Forklift operation can consume a substantial amount of energy over time and is. Forklift operators handbook a guide to safe operation rta website. The green ground wire in the ac input wiring must be connected to the charger ground stud identified by a green dot and ground symbol. Most new batteries start with 1500 cycles prior to the end of its usable battery life.
There are various styles of battery electric forklifts and range from small motorized pallet trucks to much larger forklifts. If water is extremely low prior to charging, only add enough to just cover the battery plates. Forklift batteries maintenance make your battery last. Chart of battery state of charge please make sure that when charging batteries at your shop to use the chart below. Excessive water loss might be a sign that the battery is gassing. Over or undercharging this type of battery can significantly decrease its lifespan. The industrial charger is responsible for charging the forklift battery as quickly as possible without shortening the batterys lifespan due to overheating and overcharging. Charge a forklifts battery only when it dips below 30% charge and be sure to charge it until it is full and then stop charging it. Forklift battery maintenance guide most leadacid forklift batteries provide around 2,000 charge cycles, which usually translates into about five years of service life. But even this lifespan can only be reached with proper maintenance. This chart suggests that to reach 100% state of charge you need to reach the voltage and specific gravity listed in the chart. Other applications, such as solar or offgrid may vary.
Designate an area specifically for battery charging. The results indicate that the lithium ion battery minimizes energy consumption and process time by providing trucks with opportunity charging, i. Parasitic draws can keep the forklift battery in a state of low. Your investment in electric lift trucks and industrial batteries needs to be protected in order to maximize the benefits that they have to offer. The second, and lesser known function, is to provide mass as a counterweight, which aids the forklifts lifting capacity. Date employee water added comments for battery service, or questions call 6304667700.
Battery types and charging theory convergence training. Industrial battery charger battery charger pdf manual download. This technology can save space in existing battery rooms, the labor associated with battery changes and the additional capital costs of acquiring spare batteries. That is why the eye can indicate a battery is good but it still doesnt perform properly.
It is important for the person charging a battery to begin with an appropriate inspection of the battery and charger, following all of the requirements and recommendations of the batterys and chargers original equipment manufacturer oem. Electric forklift trucks from linde material handling. Most leadacid forklift batteries provide around 2,000 charge cycles, which. For instance, keep a log of every time the battery is watered. An electric forklift is designed to operate for one shift. Record the specific gravity with the hydrometer in the service log. Return battery to forklift with lifting beam and secure in place after charging 29 cfr 1910.
Establish regular maintenance intervals for all industrial batteries to realize the full value of your. Some employers routinely change batteries instead of charging them in the vehicle. Check water level after charging and add distilled water or deionized water if water level is below level indicator record in service log. Batteries have a finite number of cycles, if you charge based on convenience instead of sticking to a schedule. An electric forklift is designed to operate for one shift and then be charged on the next shift or overnight. In part one, we will discuss charging and maintaining a forklift battery and then continue through to part two, covering cleaning and safety with a quick summary to finish off. Forklift battery charging safety will depend on many aspects, it includes forklift operators competence and compliance of the employer to osha rules and regulation.
It will cover the chemical action of charging, charging limitations, voltage. Information about forklift battery inspections, battery. It is important to charge an electric forklift battery only when the charge is below 30% as opposed to scheduling battery. For more information, see battery charging and changing procedures. Employers that focus on safety can help its personnel to maintain the workplace to be free from menace and perils. Charging an electric forklift battery at the right time is important. Properly charging a battery is all about doing it at the right time, for the right amount of time. Every time you operate a forklift or other powered industrial truck, inspect it to ensure that it is operating properly. The general rule of thumb is to recharge the battery after an.
It is very important, however, to limit the maximum battery voltage during charging otherwise the battery will be damaged. Charging batteries, including those described as maintenance free, give off hydrogen gas. This system includes a precise residual charge display, battery temperature monitoring, and a. Of course, forklift battery room ventilation requirements differ from facility to facility.
7 909 717 1405 1263 491 630 1079 1124 444 331 1422 137 586 225 183 1383 1098 604 1205 948 727 1024 148 1163 564 403 211 197 1026 1305 874 2 1308 128 431 196 373