Ask the Expert

Forklift battery care and maintenance takes dedication, planning and time.  However, proper handling and a regular charging plan will greatly increase the battery’s lifespan, saving you money and time!

Just like other battery-operated equipment, your forklift battery should not be connected to the charger until it’s at 25% capacity or below.  If you charge the battery too soon you run the risk of shortening the lifespan of the unit.  The charger should be set on “weekend” or “equalize” on approximately every 5^th charge cycle, depending on the exact model of your charger.  Be sure to review and closely follow the operation manual provided with your specific charger.  Avoid interrupting the charge cycle or using the battery for several hours after the cycle has ended.  Follow these rules and you’ll help make sure you get the most out of your battery!

One thing to always avoid is accidentally connecting the charger to the forklift rather than the battery.  This is a common mistake and can damage both the charger and the forklift.  Also, make sure the amperage of the battery matches that of the charger.  Forklift batteries shouldn’t be allowed to discharge completely as this shortens the lifespan of the battery and can also prevent the charger from activating when first connected to the battery.  If the charger can’t read any activity in the battery it won’t begin the charge cycle and a technician will likely have to re-set the charger parameters before the charge cycle can begin.

One thing that’s certain is that forklift batteries are very big, expensive and heavy.  In some cases the battery may be removed from the forklift and a second battery installed in order to prevent down time.  Great care should always be used in handling forklift batteries and there are a variety of tools and special equipment which can be used to safely remove or install a battery.  The battery handling equipment may vary greatly from one machine to another.  However, the use of proper battery handling equipment is important as it helps to avoid the potential of dropping or mishandling the battery and prevents costly battery replacement.

Follow these guidelines and you’ll be sure to extend the lifespan of your forklift battery!

Jun 8, 2010

By Don Pollard
Parts Control and Inventory Specialist

The need of a major repair often leaves us in a difficult situation. For many people, making the choice between a rebuilt or a remanufactured part is really confusing. Here are some basic differences:

Rebuilt

A rebuilt is a product where a previously failed unit is used to create a rebuilt version. While the unit is most often completely disassembled and cleaned, in many cases only the parts that fail testing may be replaced, or common wear items. Most items included in the rebuild are not new, yet often the product is re-painted to appear “like” a new or remanufactured starter, which can be quite deceiving. Quality of rebuilds can vary between rebuilders as many are done in smaller shop environments instead of a standardized factory setting.  Ultimately a rebuilder is seeking only to replace the minimum required parts to pass their own quality control testing which may or may not be the same as the OEM specifications. Generally you are asked to return your old core so they can rebuild your part for another person, and you are charged for this core until you return it. This is a common, cost effective way of getting a starter that has been rebuilt in and that passes only minimum testing. Also, the product you receive may not be identical to the one you require. You may be trading in a heavy duty sealed starter and wind up with a can-use automotive, unsealed standard duty item. It will most likely work and fit alright, but rate of failure is higher than NEW or OEM products. In order to get max application coverage with as few items on the shelf as possible, the supplier will only carry the “can use” or “may fit” parts. Usually these will come with an attractive “no hassle” parts warranty to help backup and sell the product, which by nature is going to be more prone to failure. There is a higher chance you may wind up having to replace the same item again, if one of the components that “passed” minimal testing during rebuilding later fails.

Remanufactured

This is an entirely different process in which worn products are restored to like-new condition. This is done in a factory environment where a core, used, or discarded product is completely disassembled. All useable parts are cleaned, refurbished, and put into an inventory. A new product is then assembled from these parts using new, and even updated parts for all wearing components. Often only the basic frame-type items or shell are reused. This produces a unit equivalent and sometimes superior in performance and expected lifetime to the original OEM product. Someone not wanting to sacrifice quality in a more cost effective solution to the OEM or new version should consider this. Cost savings will not be enormous, but quality is not compromised. These products are unlikely to fail again within their expected lifetime, and will be backed with a reasonable parts warranty. Again care should be taken to ensure you are receiving the identical product, especially if yours is a heavy duty or contaminated type environment.

It is clear that the situation depends upon your requirement and what money you can spend on your equipment. The bottom line is that these options are cost-effective alternatives to buying new parts, but keep in mind that every situation is different. Sometimes better options are costly but can be well worth it.