Maximize Uptime With Truck Battery Maintenance
Robust, well-maintained batteries are essential for the proper performance of Class 8 trucks. Battery failures can lead to costly downtime, delayed deliveries and driver inconvenience. Spec'ing the right batteries, maintaining them and replacing them before a failure occurs can ensure batteries are reliable and performing as they should.
“Batteries only have so many cycles, which is how many times they can be drained and charged,” said Chris Hough, vice president of maintenance design and engineering at Penske Truck Leasing.
Extreme temperatures, both hot and cold, can severely impact battery performance. Cold weather, in particular, can reduce a battery’s cranking power, while high temperatures can accelerate internal wear.
“High temperatures will reduce the number of cycles the batteries are capable of, leading to a shortened life span. Aside from that, I attribute a lot of wear to poor recharging and maintenance,” Hough said.
Getting Ahead of Issues
To help reduce the risk of battery failures, Penske Truck Leasing specs Thin Plate Pure Lead – Absorbed Glass Mat (TPPL AGM) batteries. With TPPL AGM batteries, fluid is absorbed in glass mats, so it doesn’t degrade the plates as quickly. “It is a higher quality battery,” Hough said. “They tend to last longer and take a little more abuse than our wet-cell battery.”
Penske has also transitioned to a 300-amp alternator. A 300-amp alternator can maintain the proper voltage levels even under high load conditions, helping to avoid the deep discharges and sulfation that often lead to premature battery failure. It also provides more current, allowing batteries to recharge more quickly, which is beneficial if the truck has heavy electrical loads from auxiliary systems or in-cab electronics that drain the battery faster.
Maintaining Batteries and Electrical Systems
Implementing a battery/electrical system maintenance program is essential to the systems’ health. “Periodically testing the batteries and cleaning and treating battery and electrical connections is vital to reducing unscheduled downtime,” Hough said.
As part of proactive battery maintenance, technicians connect an adequate charger to the battery pack when the vehicle is in for maintenance or service. “They also do a proper cleaning of cables and terminals and ensure proper routing of battery and accessory cables,” Hough explained.
Batteries don’t operate in isolation. They’re part of a truck’s larger electrical system, which also requires maintenance. Technicians regularly check alternators and charging systems and inspect wiring. "A systematic test of the electrical system's health can pinpoint an area of concern needing deep inspection or diagnostics,” Hough said.
Because batteries can be temperature-sensitive, they may need extra attention as temperatures drop. “If you have a good year-long approach, you will ideally align that normal maintenance prior to the colder months of the year to reduce the risk of downtime or needs for jumpstarts/service,” Hough added.
Testing Batteries
Testing batteries on a regular schedule helps technicians address potential issues before they cause failures. Load testing reveals the battery’s ability to sustain power under load conditions. If the battery doesn’t maintain adequate voltage during the test, it may need to be recharged, repaired or replaced. Voltage testing can reveal a battery that is undercharging or self-discharging, which could lead to a battery failure.
Battery testing is typically done by physically connecting a voltmeter or load tester to the battery, but new technology is making it easier for techs to get information from batteries. “We are testing batteries with an embedded chip that tracks various aspects of battery health and performance,” Hough said. “You can get a lot of information that can optimize battery maintenance and replacement schedules.”
Spotting the Warning Signs
A dead battery makes it clear that the battery needs attention, but Hough said there are warning signs. “Underperforming starting or charging system is an early indicator that a battery may fail,” he explained. “This could show up to a driver or a technician as long crank times, dim lights or underperforming accessories.”