The forklift suddenly runs for only half as long as usual. The temperature rises unusually sharply while charging. And the battery is bubbling suspiciously. Sound familiar? Then it's time to take a closer look.
Many signs of a defective forklift battery are overlooked in everyday life – or misinterpreted. Some people think it's a fault with the charger, others with the forklift itself. In fact, the battery is often the culprit. But "broken" doesn't automatically mean "replacement."
In this article, we'll show you how to recognize that your forklift battery is having problems. We'll explain the causes and provide you with clever options afterward—including regeneration or switching to certified used batteries.
How do you know if a forklift battery is defective?
There are several clear signs that indicate a damaged or worn-out forklift battery. Typical symptoms include:
- Fast discharge even though the battery is fully charged
- Shortened forklift operating times
- Charging problems despite a functioning charger
- Excessive heat generation or overheating during charging
- Discoloration or deposits on the housing or connections
- Low electrolyte level despite regular refilling with distilled water
- Outgassing or noticeable odor
- Corrosion on the electrical components
Tip: If you experience these symptoms, first check the water level , battery voltage , and terminal connections . Often, the problem isn't with the battery itself, but with the surrounding technology.
What causes can lead to the defect?
The lifespan of a forklift battery depends on many factors. Common causes of damage include:
- Deep discharge due to non-observance of the discharge limit
- Unsuitable chargers or incorrect charging cycles
- Irregular intermediate charges that stress the battery
- Inadequate maintenance , e.g. water level or cleaning
- Incorrect use of the battery type (e.g. lead-acid in high-load operation)
- Sulfation of the plates , often due to long periods of inactivity or incorrect refilling
- Temperature fluctuations or high ambient temperatures
A defective forklift battery is not always the result of a single fault, but usually the consequence of a lack of care over a longer period of time .
How can I safely check the condition of the battery?
If you are unsure whether your forklift battery is still functional, we recommend a professional field test . The following parameters are evaluated:
- Voltage under load
- Capacity test according to DIN EN 60254-1
- Cell resistances and cell voltage
- Acid density and electrolyte level
- Condition of electrical components and connections
Such a test reliably shows whether the battery is still operational , repairable or actually needs to be replaced .
What to do with a defective forklift battery?
If your forklift battery has been identified as defective, there are several options – depending on its condition and age:
Regeneration as a cost-effective alternative
Many batteries can be revived through professional regeneration . This process removes sulfation , refreshes the electrolyte , and recharges the cells. This can significantly extend the battery's lifespan – and is significantly less expensive than buying a new one.
Exchange for a used forklift battery
Many companies specifically choose tested, used forklift batteries because they are reliable and significantly more affordable. It's important to choose a trustworthy supplier like HK Handels GmbH , which offers a warranty and proof of capacity.
Professional disposal and return
If the battery is irreparable, it must be disposed of according to legal requirements . Specialist companies like HK Handels GmbH take care of the return and environmentally friendly disposal – often even with reimbursement for used batteries .
Can battery cells be replaced individually?
Yes, that's possible – and in many cases, it makes sense. If only one or two cells in a forklift battery are defective , the entire battery doesn't have to be replaced. Individual battery cells are available separately , provided the battery type is common and the rest of the battery is still in good condition.
A cell replacement may be worthwhile if:
- the battery still has enough capacity overall
- the damage is clearly limited to individual cells
- the exchange is carried out professionally
Important: New cells should always be technically compatible with the existing battery type . After replacement, an equalizing charge is required to restore the cells' balance.
How to increase the lifespan of your forklift battery
With proper care, the lifespan of a forklift battery can be significantly extended . Pay attention to the following points:
- Regular maintenance (e.g. refilling the water level with distilled water )
- No deep discharge – charge at 20% remaining capacity if possible
- Use a suitable charger that is tailored to your battery type
- Avoid intermediate charging if possible
- Ensure temperature control in the charging area
- Cleaning and checking electrical components
- Marking and regular testing according to manufacturer's instructions
Conclusion: A forklift battery defect does not always mean a total loss
Forklift batteries can operate reliably for many years – provided they are used and maintained properly . If a defect does occur, it's often worthwhile to recondition or replace the battery with a used one . This saves you money and ensures sustainability.
If you are unsure whether your battery is still usable: We will be happy to advise you personally, carry out field tests and offer tested used batteries with a guarantee .
