Maximize Productivity with Proper Battery Selection and Maintenance
for Industrial Utility Vehicles
By Elke Hirschman, Trojan Vice President of Marketing
SEPTEMBER/OCTOBER 2012
Today’s facility management professionals face a variety of challenges ranging from limited staff
to shrinking budgets which can cost both time and money when it comes to successfully
completing everyday tasks. But choosing the right battery for lift trucks, material handling
equipment and facility service vehicles such as golf cars is vital to the success of your business.
Understanding proper battery maintenance and educating your staff are a few important ways to
ensure the safe, uninterrupted operation of vital facility management equipment, and key to
getting the biggest return on your battery investment.
So what battery technology is right for your application? There are several battery technologies
on the market today, and each offers features and benefits that will fit the equipment needs
required by today’s facility managers. Deep-cycle batteries, whether they are flooded, AGM or
gel, are the best choice for the wide variety of industrial utility vehicles and mobile equipment
available today. The technology incorporated into deep-cycle batteries is specifically designed
for the deep battery discharge characteristics of this type of equipment.
Flooded Batteries
FLA – Flooded Lead Acid
FLA, or flooded, batteries provide the best cycling performance of all deep-cycle battery
technologies and is an ideal option where lowest cost is a key deciding factor. To achieve
maximum potential cycle life, flooded batteries require regular maintenance. As FLA batteries
charge, hydrogen gas is produced and vented in the process. This off gassing of hydrogen
reduces the electrolyte level in the flooded battery, so periodic “watering” of the batteries is
required to ensure maximum life. The frequency will need to be determined on the equipment
and application.
Overview of AGM & Gel
VRLA – Valve Regulated Lead Acid
If maintenance cannot be guaranteed on a regular basis, flooded batteries are not a good
choice. For applications that require maintenance-free battery technology, you should consider
a sealed battery such as AGM or gel (VRLA) technology, which do not need watering. However,
while maintenance-free batteries provide more convenience, that convenience comes with a
price. Sealed VRLA batteries are going to be more expensive and will have lower cycle life
when compared to FLA batteries. While AGM and gel batteries batteries do not have openings
to add water to the cells, they do “off gas” so there should have good ventilation when charging.
Tips for Proper Maintenance
Regardless of whichever battery technology you choose, it’s important to remember that a
battery is only as good as the maintenance it receives. Proper maintenance of deep-cycle
batteries will provide maximum performance and long life extending your overall equipment
runtimes. Following these simple steps ensures that your equipment’s batteries will enable you
to operate at optimum levels day in and day out.
Safety
The safety precautions and procedures outlined below should be followed whether handling
flooded, AGM or gel batteries.
•
Always wear protective clothing, safety glasses, and gloves when handling and/or performing
battery maintenance
•
Never add acid to a battery
•
Keep batteries clean and dry.
•
Keep sparks, flames and cigarettes away from batteries
•
Charge only in well ventilated areas
•
Skin contact with electrolyte should be avoided
Inspection
•
Examine the outside appearance of the battery. The tops of the batteries and terminal
connections should be dry and clean, free of dirt and corrosion.
•
If fluids are on the top of a deep-cycle flooded battery this may mean that the battery is being
over-watered or overcharged. If fluid is on the top of a deep-cycle AGM or gel battery this
means that the battery is being overcharged, which will reduce the performance and life of the
battery.
•
Check battery cables and connections. Replace any damaged cables and tighten any loose
connections.
Watering – Flooded Batteries Only
Water should never be added to deep-cycle AGM or gel batteries, as they do not lose water
during use. Deep-cycle flooded batteries need to be watered periodically. The frequency
depends upon battery usage and operating temperatures. Check new batteries every few weeks
to determine the watering frequency for your application. It is normal for batteries to need more
watering as they age.
•
Fully charge the batteries prior to adding distilled water. Only add water to discharged or
partially charged batteries if the plates are exposed. In this case, add just enough water to
cover the plates and then charge the batteries. Continue with the watering procedure below.
•
Remove the vent caps and place them upside down so that dirt does not get on the underside
of the cap. Check the electrolyte level.
•
If the electrolyte level is well above the plates then it is not necessary to add more water.
•
If the electrolyte level is barely covering the plates, add distilled or de-ionized water to a level
1/8” (3 mm) below the vent well (this is the plastic shield inside the vent hole) for standard
batteries.
•
After adding water, secure vent caps back on batteries.
•
Tap water may be used if the levels of impurities are within acceptable limits. Check your
battery user’s manual for suggested limits.
•
Single-point watering systems also are available to the take the mess and guesswork out of
properly watering flooded batteries. Trojan’s HydroLink watering system simplifies battery
watering maximizing the performance and life of Trojan’s deep-cycle flooded batteries. With
Trojan’s HydroLink advanced single-point watering system, precise battery watering is made
easy, saving time and money when on the job.
Cleaning
Observe the battery for cleanliness at regular intervals and keep terminals and connectors free
of corrosion. Terminal corrosion may adversely affect the performance of the battery, and it
could present a safety hazard.
•
Check that all vent caps are secured properly on the battery.
•
Clean the top of the battery, terminals and connections with a cloth or brush and a solution of
baking soda and water (1 cup of baking soda to 1 gallon of water). Do not allow cleaning
solution to get inside the battery.
•
Rinse with water and dry with a clean cloth.
•
Apply a thin coat of silicone gel or terminal protector spray that can be purchased through
your local battery dealer.
•
Keep the area around batteries clean and dry.
Charging
Proper charging is imperative to maximize battery performance. Avoid under- or over-charging
because this can significantly reduce the life of the battery. For proper charging techniques,
refer to the instructions that came with your equipment. Most chargers are automatic and preprogrammed, while others allow the user to set the voltage and current values.
•
Make sure the charger is set to the appropriate program for deep-cycle flooded, AGM or gel,
depending on the type of battery you are charging.
•
Batteries should be fully charged after each use.
•
Lead-acid batteries (deep-cycle flooded, AGM or gel) do not have a memory effect and
therefore do not need to be fully discharged before recharging.
•
Charge only in well-ventilated areas.
•
Check electrolyte levels to make sure plates are covered with water before charging (deepcycle flooded batteries only).
•
Check that all vent caps are secured properly on the battery before charging.
•
Deep-cycle flooded batteries will gas (bubble) towards the end of charge to ensure the
electrolyte is properly mixed. Do not be alarmed, this is normal.
•
Never charge a frozen battery.
•
Avoid charging at temperatures above 120°F (49°C).
Equalization – Flooded Batteries ONLY
Equalization is an overcharge performed on deep-cycle flooded batteries after they have been
fully charged. Trojan recommends equalizing only when batteries have low specific gravity,
below 1.250 or wide ranging specific gravity, > 0.030 points between cells, after fully charging a
battery. Deep-cycle AGM or gel batteries should NEVER be equalized.
•
Confirm that the batteries are deep-cycle flooded.
•
Check electrolyte levels to make sure plates are covered with water before charging.
•
Check that all vent caps are secured properly on the battery before charging.
•
Set charger to equalization mode.
•
The batteries will gas (bubble) during the equalization process. Do not be alarmed, this is
normal.
•
Measure the specific gravity every hour. Refer to your equipment user’s manual for specific
gravity and voltage measurements. Discontinue the equalization charge when the gravity no
longer rises.
Storage
•
Always charge batteries before placing in storage.
•
Store in a cool, dry location, protected from the elements.
•
Disconnect batteries from equipment to eliminate potential parasitic loads that may discharge
the battery.
•
Batteries gradually self-discharge during storage, so monitor the specific gravity or voltage
every 4-6 weeks. Stored batteries should be given a boost charge when they are at 70% state
of charge or less. Refer to Table 7 for specific gravity and voltage measurements.
•
When batteries are taken out of storage, recharge before use.
Torque
•
Tighten all wiring connections per the manufacturer’s specifications.
•
Do not over-tighten which can result in post breakage.
•
Avoid under-tightening which can result in post meltdown or fire.
•
Make sure there is good contact with the terminals.
Conclusion
By gaining a clear understanding of the various battery technologies available on the market
today and committing to a regular maintenance schedule, ensures that whichever battery type is
used for your facility management equipment it will continue to operate at peak levels of
performance and reliability. With proper care and maintenance, an initial battery investment can
be extended as well as keep the total cost of ownership to a minimum resulting in more time on
the job.
For additional tips on battery maintenance, visit Trojan Battery’s “Trojan Tips” video tutorials at
www.trojanbattery.com/videos.
About the Author:
Elke Hirschman is vice president of marketing for Trojan Battery Company. She is responsible for leading Trojan's overall
global product and business marketing efforts for its floor cleaning, golf, transportation, aerial platform and recreational
product divisions. Hirschman oversees product development, pricing policies, and sales and marketing strategies for
Trojan's domestic and international operations. During her tenure at Trojan, Hirschman successfully launched the company's
AC Series floor machine batteries, the HydroLink™ watering system for deep-cycle flooded batteries, the OverDrive AGM
31™ anti-idling battery for heaving trucking applications, and the industry-leading AGM and gel battery products