Why the Batteries of My Floor Scrubber Machine Losing Power Quicker Than Before?
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If your floor scrubber machine's batteries are losing power quicker than before, there are a few common culprits to check out. Here’s a breakdown to help you troubleshoot:
Battery Health & Maintenance
1. Age of the Batteries
Most deep-cycle batteries used in scrubbers have a lifespan of 2–5 years. If yours are getting up there in age, they may simply be wearing out.
2. Undercharging or Overcharging
- Undercharging happens if the batteries aren’t being charged fully between uses.
- Overcharging can occur if the charger isn’t shutting off properly or is left plugged in for too long.
- Eco-smart tip: Use a smart charger that automatically stops when the battery is full.
3. Dirty or Corroded Terminals
Corrosion at the battery terminals can create resistance, causing the batteries to lose power more quickly. Give those terminals a clean with a mix of baking soda and water (and always wear gloves).
Usage Patterns
4. Increased Workload or Operator Habits
Are you using the machine more intensively or on rougher surfaces than before? That draws more power. Also, high brush pressure or vacuum settings can drain batteries faster.
5. Infrequent Use
Believe it or not, not using the scrubber regularly can also hurt battery life. If the machine sat unused for a while or wasn’t charged right after use, sulfation could have set in—this reduces how much energy your batteries can store. Load testing at a battery service center can confirm this.
Mechanical & Electrical Issues
6. Worn Brushes or Squeegees
When these parts wear down, the machine works harder to do the same job—draining the battery faster.
7. Motor or Controller Issues
A dragging brush motor, clogged vacuum motor, or faulty wiring could be drawing excess power. Might be worth a technician’s inspection.
Daily Battery Care (End of Each Shift)
| Task | Lithium | Lead-Acid |
| Charge battery after use | ✅ | ✅ |
| Allow battery to cool before charging (15–30 min) | ✅ | Optional |
| Check charger is functioning properly | ✅ | ✅ |
| Clean any dust or dirt from battery area | ✅ | ✅ |
| Inspect battery casing for cracks/swelling | ✅ | ✅ |
| Inspect battery terminals/cables for corrosion | ✅ | ✅ |
| Confirm proper connection to charger | ✅ | ✅ |
💡 Don’t store batteries fully charged for long periods if idle. For best health, lithium batteries prefer 60–80% storage charge.
Weekly Battery Care (Once Per Week)
| Task | Lithium | Lead-Acid |
| Check runtime vs normal performance | ✅ | ✅ |
| Measure resting voltage (multimeter) | ✅ | ✅ |
| Check for signs of battery swelling or heat damage | ✅ | ✅ |
| Inspect cables, terminals, and connectors | ✅ | ✅ |
| Clean battery terminals if needed | ✅ | ✅ |
| Review charger function (check LED/voltage) | ✅ | ✅ |
| Confirm charger shuts off after full charge | ✅ | ✅ |
| Inspect charger cord & plug for damage | ✅ | ✅ |
| For flooded lead-acid: check & top off electrolyte levels | ❌ | ✅ |
| Run system under load & monitor voltage drop | ✅ | ✅ |
💡 For lithium packs: avoid charging in high-heat environments. For lead-acid: clean corrosion with baking soda + water and a brush—no metal tools!
Monthly Tip
Do a deeper performance review:
- Measure runtime consistency over several days.
- If you notice run time dropping 20–30% compared to new, consider battery load testing.
- Log everything—it helps if you ever need to file a warranty claim.
Eco-smart tip:
Don’t store at 100% charge long-term. If you plan to leave the machine idle for over a week, discharge the battery to around 60–70% and unplug it from the charger.
How to Perform a Load Test on Batteries
📦 Applies To:
- 24V Lithium-ion / LiFePO₄ batteries
- 24V Lead-acid batteries (Flooded, AGM, Gel)
🧪 STEP-BY-STEP LOAD TEST PROCEDURE
🧰 What You’ll Need:
| Tool | Purpose |
| ✅ Multimeter | Check voltage before/after the test |
| ✅ Battery load tester (match voltage/type) | Simulates real-world electrical draw |
| ✅ Stopwatch or timer | Time the load duration |
| ✅ PPE (gloves/eyewear) | Especially for lead-acid systems |
1. Fully Charge the Battery
Before any test:
- Use the manufacturer’s charger
- Let the battery rest for 30–60 mins after charging
- Record starting open-circuit voltage with a multimeter:
- 24V Lithium: ~25.6–29V
- 24V Lead-Acid: ~25.2–25.6V
2. Apply a Load
You want to simulate real usage (without overdoing it).
For Commercial Floor Scrubber Batteries:
- Use a load equal to 50% of the battery’s rated amp-hour (Ah) capacity
E.g., for 100Ah battery → apply a 50A load
Options:
- Use a digital battery load tester (rated for 24V)
- Or run the scrubber machine under normal operation (full brush & vacuum)
3. Monitor the Voltage Under Load
| Battery Type | Good Voltage Under Load | Caution Zone | Failing Battery |
| Lithium (24V) | >23V | 22–23V | <22V quickly |
| Lead-Acid (24V) | >23V | 21.5–23V | <21.5V quickly |
- Test duration: 5–10 minutes for best results
- For formal testing, some follow a 15-second pulse test with fixed amperage
4. Watch Recovery Time
Stop the load and:
- Wait 1–2 minutes
- Voltage should bounce back close to original resting value
If it stays low, the battery might have reduced capacity or internal resistance issues.
Extra Checks by Battery Type:
LITHIUM:
- Check BMS (Battery Management System) for fault codes or shutoffs
- Ensure your tester is compatible with lithium (not all are)
LEAD-ACID:
- For flooded types: check electrolyte levels before testing
- Clean any corrosion before connecting your load tester
Eco-smart tip:
💡 Testing your batteries every quarter can prevent surprises—and save hundreds in machine downtime or premature battery replacement.