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Maintenance Tips for Industrial batteries


A normal truck battery makes up 30% of the value of a new truck and can work for about 6,000 hours. It will be your fuel for the next five years or more, as long as you follow the manufacturer's instructions for maintenance.

In our tips and practices list, we provide helpful tips to help you avoid common mistakes and keep your battery (and truck) in top condition.

industrial battery

1. Battery charge

Total discharge damages the battery and causes the truck's electrical components to stop working. This causes significant damage to the truck, engine failure and component burnout.

As if this were not enough, the truck stops working optimally. When the battery is 80% discharged, the traction and hydraulics of the truck slow down, indicating that it is time to charge it. If the industrial battery is discharged, you will need to fully charge it for an uninterrupted period of 8 hours and never disconnect the battery from the charger without completing the process.

2. Check the water level periodically and maintain the level always after charging.

Water is critical to the operation (and life) of the battery. During the charge cycle, the water heats up and dissociates into two gases, releasing bubbles of hydrogen on the negative plates and oxygen on the positive plates. The plates are exposed to the air when the water level in a battery drops too low. This causes the active material on the plates to dry out and become brittle, causing permanent damage.

For this reason, it is essential to add distilled water to the battery on a regular basis (usually every 5 to 10 charges). Be careful not to add too much water. If the water level goes above the mark, it will spill… causing permanent damage.

Add the water after charging the battery, not before.

3. Watch out for industrial battery maintenance.

Be attentive to sulphation that deteriorates the connections, connector screws of your battery, in which case it is necessary to change these components so that the battery works correctly. Ask us for the necessary spare part to put the battery in optimal condition.

Clean the battery's sulphated terminals and protect the connection terminals with antioxidant grease to prevent sulphation.

4. Let the battery rest during lunch.

You are often tempted to quickly charge the battery during short breaks. In the industry it is known as "occasional loading". Battery life depends on charge cycles (that is, the number of times it is charged). Short charge cycles slowly reduce the effectiveness of the battery until it stops charging. Instead of charging the battery, let the truck cool down during stops.

5. Be careful with fast charge cycles.

Fast charge cycles can cut downtimes by 10%, but they come at a price. Although all battery systems can be charged quickly, the heat generated during the process can dramatically reduce the life of lead-acid batteries. In lithium and nickel batteries the same thing happens, but to a lesser extent. Any experienced dealer or battery supplier can advise you on how to avoid temperature control problems while increasing productivity.

RESERVE fast charge cycles for emergency situations.

6. Protect your charger.

The charger is an important investment; it must be stored in a safe place to avoid deterioration. It should be kept away from moving trucks and plant equipment. Make sure that the cables and plugs do not touch the ground so that they do not get crushed under the wheels.

Measures to be taken:

  • Do not charge the battery when it is a little discharged or you will end up with it prematurely.
  • Before disconnecting the battery from the charger, make sure the charge cycle is complete.
  • Add distilled water only.
  • Replace damaged or sulfated flexible bridges and screws
  • Check the condition of the battery plug and connector periodically.
  • Electric batteries produce a gas mixture that is explosive at a concentration of only 4%.
  • Battery charging areas are dangerous, given the existing ventilation, ignition, electrical and environmental hazards.
Contact JPAC Batteries, if you need assistance on maintaining your industrial batteries.


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