If you are looking to effectively cut battery maintenance costs, you should learn more about battery watering kits. Battery watering kits provide a safe, reliable, and time-saving process for filling batteries.

BATTERY ACID

Battery acid, or sulfuric acid, is the main component of a lead-acid battery. Sulfuric acid is an electrolyte or liquid found in lead-acid battery cells. In addition to the sulfuric acid solution, batteries also contain water.

WHY DO WE NEED TO WATER A BATTERY?

A standard industrial, lead-acid battery consists of water to fulfill the sulfuric acid solution. After a battery is charged, it is important to check the water level to ensure that it is at a functional level for the lead-acid battery to continue its normal daily operations. A lead-acid battery’s functionalities are limited or defective when water levels dip too low or are absent altogether. Lead is a metal, any metal that is not maintained in the proper condition will rust, in this case damage the battery. That is why it is important that the water level in the battery is continually maintained.

The power from a lead-acid battery is created by the chemical reaction between the water and acid contained inside the battery. When a lead-acid battery is charged, the water inside the battery is consumed during the chemical reaction through which energy is created. Water also evaporates over time. When the water inside the battery is gone, the battery is dead. A battery watering kit prevents this type of deterioration and failure.

BATTERY WATERING KITS

Battery watering kits come with a single-point watering system that is either fully assembled or that must be assembled after purchase. The kit comes with neatly labeled diagram with instructions for an easy install. The kit consists of a series of tubes with multiple valves connected to them; the number of valves is equal to the number of cells in the battery. The battery watering kit is hassle-free and no tools are needed for assembly. Remove the battery cap, connect the kit, and then connect the water hose. Each cell is then filled up to the proper level. An indicator on the watering valves alerts you when water reaches the correct level. This indicator is designed for a wide visibility and can easily be seen from a distance. When each battery cell is appropriately filled, the water will automatically shut down. Repeat this process whenever the water level in the battery is low.

BATTERY WATERING KIT ACCESSORIES

Following the charging period of a battery, it is important to check the water level in an industrial lead-acid battery. Traditionally, this is done by taking the cap off each cell and making sure the water level is right within the levels of the battery plates (located inside the battery, are visible when you look inside the battery through the vent cap holes). While this is a tedious and time-consuming process, it is necessary to maintain a battery’s working condition. This is where a battery water monitor will save you all the time, money, and labor.

Battery Water Monitors - - - A Battery water monitor is designed to be your eyes and ears inside the battery. The monitor is equipped with a bright LED visual indicator that alerts operators when it is time to water the battery. The battery water monitor will improve a battery life and eliminate over- and under-watering of batteries. Just like the battery watering kit, the battery water monitor is easy to install can be placed on any battery cell for an accurate read.

Watering Gun - - - The watering gun is helpful for manually filling each cell by hand. It is a safe and efficient method of watering batteries without an automatic watering system. A manual watering gun can be connected to a standard hose or deionizer. Place the tip of the gun into each individual battery cell and squeeze the trigger to continue the process.

Gravity Tank - - - A gravity tank is a simple device for filling single-point watering systems. The gravity tank is ideal to assist in applications in which the water will be plumbed into the tank. There is no need to fill the tank manually and the gravity tank can water multiple batteries at one time. Gravity tanks should be positioned a minimum of three feet above the batteries and should be properly secured to ensure proper and efficient water delivery to the battery cells.

Direct Fill Link - - - Direct fill links can be used with a hose (connected to a janitor’s sinks, or spigot somewhere in the warehouse) or a portable water tank. The direct fill link operates like a watering gun equipped with a flow indicator wheel. Also, it is equipped with a pressure-sensitive handle and a connector like a garden hose connection. The direct fill tank does not include a handle lock, which makes it safer to operate because it will immediately shut off if left in a battery, eliminating the possibility of overfilling. The flow indicator encased in the PVC makes it both durable and lightweight. The DF72 model is fast enough to fill a large battery but gentle enough to fill small delicate battery without the risk of overflow.

 

STEP-BY-STEP PROCESS OF INSTALLING A WATERING KIT

1. After your battery is charged, remove all the vent caps on the battery cells.
2. Using the diagram, snap the battery watering kit into place making sure the valves are snapped in place on each cell.
3. Connect a hose to the watering kit.
4. Turn the water on.
5. Wait until all the indicators on the valves show that each cell has been watered to the proper level. The water will automatically shut down once each cell has been watered to the appropriate level. Once this process is complete, you can remove the watering kit and repeat this process with another battery.

Installing A Fully Assembled Watering Kit: https://www.youtube.com/watch?v=4TDJ-tLaKd4

(If you have a battery water monitor, follow this same process once the monitor indicates that the battery needs watering and you have completed charging the battery.)

For more information on Battery Watering Systems and related items, please visit https://materialshandlingstore.com/

If you need help or advice on the products in our online store or have a question, we would be delighted to serve you. We will respond as fast as possible—within one business day during business hours in the Pacific time zone in the western U.S.

Please contact our warehouse experts at: 844-445-1119

 

 

Warehouse safety is preserved and continuously improved through the cooperation of the operators and pedestrians. Both operators and pedestrians have a responsibility to maintain and ensure safety. The first steps to safety on the move in any warehouse is to understand and know the rules. There needs to be constant communication of your intentions as a pedestrian and an operator in a warehouse; working together to sustain and keep everyone safe. Here are some essential safety measures for pedestrians and operators on the move.    
 

STEPS TO SAFETY ON THE MOVE: PEDESTRIANS

1. Use dedicated pedestrian walkways: Always be aware of your surroundings. There are many moving parts inside a warehouse and it is critical that you stay alert and make sure you are using the pedestrian walkways. Click here to see the pedestrian safety products we offer on the store.

2. Stop, look, and listen for oncoming traffic: In addition to using the pedestrian walkways, be aware of oncoming traffic. Always remember to not only stop and look at what is around you but also listen and anticipate traffic. Blue lights, horns, and other alarms are always a great addition to your forklifts to increase spatial awareness.

3. Make eye contact with operator: Take extra precautionary measures on dealing with lift truck operators. The noise level inside warehouses often does not allow for verbal communication with the operator: make eye contact with driver when you need their attention. Make sure they are at a full stop before proceeding across traffic.

4. A lift truck needs adequate time to stop: It is essential that pedestrians and operators work together to ensure safety. Pedestrians need to give ample time for operators to stop and operators need to be wary of the speed at which they are driving their lift trucks. Operators need to come to full stop to allow pedestrians across traffic.

5. Stand clear of lift trucks in operation: Maintain a good distance away from operating lift trucks. Lift trucks have many moving parts with multiple angles and turn points. It is critical to keep clear of lift trucks that are in operation. For intersections, a simple stoplight or blind corner warning system can make a big difference. 

STEPS TO SAFETY ON THE MOVE: OPERATORS

1. Give Pedestrians the right-of-way: Pedestrians always have the right-of-way. Always check your surroundings when maneuvering through the warehouse. Pedestrians may not always be in the designated walkways. Never assume that the pedestrian will stop to let you pass before crossing, take extra measures and let the pedestrians go first.

2. Never drive up close to anyone: It is critical for the safety of the operator and the pedestrians that operators maintain a good distance between one another. This allows the operator enough time to react in case of an emergency.

3. Look in the direction of travel: Make sure you are focused on the direction the lift truck is travelling. Avoid distractions, and make sure you are at a full stop before focusing your attention elsewhere. By assessing the path towards the direction of travel, you will allow enough time to react and come to a full stop.

4. Stop and sound the horn when approaching an intersection or crosswalk or exiting an aisle: It is important for operators to become familiar with the warehouse and be aware of the blind spots and aisle areas. Operators should always stop and sound their horn when approaching an intersection, a cross walk, and while exiting an aisle. This allows for pedestrians and other lift trucks on the floor to hear and see where traffic is coming from. Click here to see our selection of horns and crosswalk safety accessories.

5. Approach and leave aisles slowly: Maintain a slow speed when approaching and leaving an aisle. By doing so, it not only allows enough time for the operator to react and but also pedestrians and other lift trucks on the floor as well.

 
National Forklift Safety Day is June 13, 2017. To order a FREE poster with any purchase using the code SAFETY2017. To see our selection of operator and pedestrian safety training kits CLICK HERE

by Dani LaMarche

Quality forklift service depends on the right tools, the following is our list of the top 5 forklift mechanics tools.

1. Camberjack: A camberjack is used to lift an orderpicker so that the load wheels can be changed. Instead of spending 10 minutes using a regular jack to get the base legs off the ground, you simply slip the wheels of the camberjack under the base leg, push the handle down, and you’re ready to change one side.

2. Crimping Tool: A crimping tool is used to crimp ends onto cables when making cable assemblies. This tool will speed up making cable assemblies by eliminating a trip to get a cable assembly made. This tool has different sizing options to crimp just about any cable end. Simply place your end on the cable and use this tool to securely crimp it in place. Then your cable assembly is ready to be installed.

3. Chain Gauge: A chain gauge is used to measure chains on your forklift. It helps a mechanic determine if the chain needs to be replaced or if it is still in good shape. Simply use the chain gauge’s guide to determine if the links match up; if not, the chain needs to be replaced or tightened up. If the guide and the chain links match, then the chain is still in good working shape.

4. Pistol Grip Grease Gun: A grease gun makes quick work of greasing forklift masts, load wheels and so on. The gun operates at 6,000 PSI and includes an 18-inch nozzle extension. Just slip the opened tube of grease inside the blue holder and you’re ready to go.

5. Altimeter: A digital multimeter measures AC/DC voltage, AC/DC current, resistance, capacitance, frequency, and duty cycle. This tool will help diagnose electrical problems, and prevent electrical problems while working on a forklift. To use, simply turn the dial to the desired measurement, plug in the leads, and power on the altimeter.

by Dani LaMarche

Floor coatings for the garage and beyond

Those who have experience working around industrial concrete flooring can tell you that it’s not as easy to maintain as one might assume. There’s a reason that the floor coatings business exists, and is so successful. Here are a few reasons it might be time to consider adding a floor coating to your facility.

Coated floors look better

One of the most obvious advantages of having a coated floor is that the end result looks much more attractive to both staff and visitors than its bare concrete counterpart. With options including multiple colors and styles, you can be as creative as you want with your warehouse flooring design. Applying a lighter color can even increase visibility and light reflectivity up to 100 percent, and save energy consumption in the long run.

Floor coatings are easier to maintain

Another one of the benefits of floor coating in your warehouse is cleaning. If you have ever tried to clean a bare floor with an automatic scrubber, you know that it can be a daunting task. Dirt magically seems to multiply and then sticks to everything including cracks in the floor and open control joints. Over time, that settled dirt slowly erodes the concrete causing a fine airborne dust that has the potential to result in respiratory problems for employees as well as damaging product and causing more work for those that have to eventually clean it off during distribution. Once a floor coating has been applied, it adds an easily cleaned, protective layer to prevent dirt from wearing down your floor. A floor coating also keeps the concrete from disintegrating and causing a dusty, unpleasant environment.

Floor coatings save you money

Urethane mortar and epoxy slurries have wear and compressive strengths that are five times greater than standard density concrete. This means you can rest assured that your floor will be able to withstand much more use and weight without damage, which minimizes your maintenance and repair costs. A professionally coated floor will also ensure that your floors are even and safe. Coated floors ideally reduce hazards that stem from employees tripping, or damaging equipment while driving over rough or uneven flooring.

How do floor coatings fit your application?

No matter what environment you work in, there is a floor coating solution to keep your employees and your products safe while in your facility. Some of the available options include:

• Slip resistant – A floor coating can be supplemented with varying anti-slip additives for use in wet or dusty environments. These additives are also useful for manufacturers or distributors of goods with oils, and dry or loose ingredients. Slip-resistant flooring are ideal to increase traction with vehicles on ramps, or tugs in hangars.
• Chemical resistant – Chemical-resistant flooring is great for industries that deal with any chemical products, or are at risk for toxic spills including oils, hydraulic fluids, and jet fuels, They’re also ideal for battery charging areas. A chemical-resistant coating prevents stains, erosion, soil contamination, and water contamination.
• Waterproof – Waterproof coatings keep water from intruding on lower-level floors or areas in which expensive water damage could occur
• Anti-vibration – Anti-vibration coatings are great for isolation underneath equipment that causes heavy vibrations. They’re also perfect for high traffic areas, such as decks or mezzanines, which can cause unwanted noise and damage from repetitive tremors.
• Anti-static – Anti-static flooring protects valuable equipment from electrical damage, as well as electronics from static charges. They’re great for the transportation or manufacturing of weapons because it reduces the occurrence of accidental detonation. Anti-static flooring is also used to prevent static build-up in grain elevators and silos.

If you are interested in learning more about the floor coatings available, or getting a quote for your facility, please contact The Materials Handling Store at 1-844-445-1119 email us at store@raymondhandling.com for more information.

By Bryan Bass

Regardless of your budget, these five ways to extend your forklift battery life will save money and increase the longevity of your battery.

1. Correctly Charging Your Battery: To properly charge your forklift battery, it should only be done once it has reached below a 20 percent charge. Once the battery is fully charged, be sure to stop charging and unplug the battery from the charger. Over- or under-charging your battery can seriously decrease its lifespan.
2. Regularly Equalize Your Battery: “Flooded” or “wet” batteries should be equalized on a regular schedule. Equalizing reverses the chemical process of stratification. Stratification happens when the battery acid becomes more concentrated at the bottom of the battery and therefore, becomes less able to hold a charge. Equalizing rebalances the electrolyte concentration as well as helps to remove sulfate crystals from the battery plates. Batteries vary on how often they need equalizing. Be sure to check the maintenance schedule for your battery before you begin the process.
3. Check Fluid Levels: All watered batteries require you to check the levels regularly. As a rule of thumb, check your levels every fifth charge cycle. As a precaution, be sure your battery is cooled down before you open the caps. Check two or three cells. If you are unsure, then check all cells. If you need to add water, follow the steps below.
4. Maintain Proper Water Levels: Be sure to only put enough water to cover the plates. Never over-fill your battery. Space is needed for the expansion that takes place during use. Only water a battery once it is fully charged. For best results, we recommend a battery watering system that stays connected to your battery. You can connect your water source to the watering system, and it will fill to the proper levels automatically, every time. This, too, will save money and time. Proper PH is very important when watering your battery. A PH between 5 and 7 is best, and is within the recommended limits for impurities. Improper PH can cause damage to your battery.
5. Maintaining Your Battery at a Safe Temperature: Industrial Batteries are pretty tough. However, extreme temperatures can quickly destroy a battery. Consider your ambient temperature while in use. The operating temperature of your battery should never exceed 113 degrees Fahrenheit. One way to help cool down your battery is to make sure there is plenty of airflow around it.

All batteries have a limited life span, however, these simple steps can extend the life of your battery by months or even years.

Have additional questions, take a look at some of our other forklift battery resources:

• Forklift battery FAQs
• Battery FAQ maintenance and care
• What is a forklift battery charger?
• Different types of charging technologies
• What is a battery spill kit?
• Forklift batteries and accessories