Forklift Battery Care and Maintenance

Forklift Battery Care

Aside from being a power source, forklift batteries also provide enough mass to serve as an effective counterweight which aids the equipment’s capacity to lift. To get the most out of forklift batteries, battery type, use, and maintenance must be considered.


Types of Batteries


When it comes to electric forklift batteries, there are two distinct types, lead-acid and lithium-ion. Since the technology involved in different battery types differs greatly, the level of maintenance and care they need also differ. 


Lead Acid – Lead acid-type batteries were invented somewhere in 1859. Using the same technology as traditional automobile batteries, they are considered the time-tested solution for electric forklifts. Lead acid batteries will last about 1,000 up to 1,500 cycles.


Lithium-ion – The lithium-ion battery was invented in 1991. Although they cost more than the traditional lead acid battery, they are more cost-effective because it requires less complex maintenance and lower running costs. Lithium-ion batteries tend to last around 2,000 to 3,000 cycles. 


Maintenance of Electric Forklift Batteries


It is very important to perform correct maintenance to prolong the life of forklift batteries. 

  • Batteries should be cleaned about once a month with warm water or battery cleaner to prevent any long-term issues.

  • Lead-acid batteries require water top-ups regularly for optimal functioning. If water is allowed to drop too far, it can result in permanent damage needing untimely forklift batteries replacement.

  • When a battery is allowed to remain at a low charge for a long period, the sulphur can start to cause damage to the point that the battery becomes useless.  

  • When charging, the battery’s voltage must match the charger’s output voltage. For example, you will need to use 24 volt battery chargers for 24v batteries. Otherwise, there is a high risk of damage to the battery, charger, or both.

Signs Batteries May Need Replacement


The most obvious sign that you need forklift batteries replacement is when they no longer hold as much charge as they did.

Other signs include:

  • Smoke

  • Flickering or dim displays

  • Signs of corrosion on the battery case

  • Smell like rotten eggs

  • Spilled acid on battery exterior

  • Terminals are damaged or corroded

  • Response time is slow

When there is smoke, the forklift must be powered down immediately to prevent the battery from catching fire or exploding. Signs of corrosion, damaged terminals, and acid leakage may require professional handling.
Location: Australia

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