Staplerbatterie Ersatzteile – das lässt sich ersetzen – HK Handels GmbH

Forklift batteries are among the most costly but essential components in forklift operations . To ensure the full capacity and service life of your battery, it's worth replacing defective or worn components with suitable spare parts in a timely manner – rather than investing in a new battery straight away. In this article, you'll learn which parts can be replaced in forklift batteries , when replacement is worthwhile , and what to consider when selecting one.

You can replace these spare parts for forklift batteries specifically

1. Battery cells (PzS, PzB, armor plates)

In traction batteries such as the classic PzS or PzB forklift batteries, the battery consists of several individual cells. If individual cells show a significantly reduced voltage or capacity, they can be replaced selectively – rather than replacing the entire battery.

Tip: Pay attention to the type plate and the nominal voltage , e.g. 24 V, 48 V or 80 V, to find the right cell.

2. Battery cables & cable sets

Defective or corroded battery cables significantly impair the charging and discharging process. Excessive heat transfer can even lead to failure. Replacement is particularly worthwhile for older forklift batteries to increase reliability.

for 24 V, 48 V and 80 V batteries
available for Toyota , Linde , Jungheinrich & other manufacturers

3. Pole screws, cell connectors & plugs

Terminal screws secure the electrical connection between the cells, but can be damaged by acid stratification , corrosion, or mechanical stress. Plugs or floats for monitoring the battery level should also be replaced if they show visible wear.

4. Housing parts & cell holders

Cracked brackets or damaged cell covers compromise safety and should be replaced with suitable spare parts – ideally with original dimensions and materials.

Why replacement is worthwhile – instead of completely new purchasing

The targeted replacement of individual components extends the battery's service life , increases operating efficiency , and significantly reduces downtime. Preventive replacement is particularly worthwhile in commercial fleets with regular forklift use – especially for traction batteries that are charged and discharged daily.

Repairing, replacing or reconditioning a battery – what is really worth it?

A new battery isn't always necessary. Those with the necessary expertise can replace certain components—such as cells, cables, or terminal connections —themselves. However, in many cases, professional reconditioning is the better option.

At HK Handels GmbH we offer you two fast and cost-effective alternatives:

Used forklift batteries : Immediately available, technically tested, with documented capacity – ideal for urgent needs.
Reconditioning your own battery : We'll pick up your battery, thoroughly inspect it, and replace worn parts. This saves you time, materials, and often money.

Especially in commercial operations, it is worth comparing – we will give you honest advice on whether repairing, exchanging or replacing your forklift battery is really worthwhile.

When you should rely on professionals for forklifts

For safety and liability reasons, some work on the forklift battery should not be performed by the operator. These include, in particular:

Replacing individual cells (e.g. PzS or PzB batteries)
Working on the electrical connection and terminal screwing
The installation of Aquamatic systems
Selecting and setting up suitable chargers

Incorrect handling can lead to short circuits , loss of capacity , or even hazardous materials accidents . Our experienced technicians handle these tasks professionally and in accordance with manufacturer specifications – nationwide and manufacturer-independent.

Are you unsure whether an exchange is possible or makes sense?

We will be happy to advise you and help you find the right solution for your forklift battery.

Increase service life: care, maintenance and regular inspection

Spare parts only help if proper care and maintenance are also provided. Pay attention to:

Regular visual inspection for wear
Cleaning the battery terminals
Refill with distilled water if required
Even circulation of the electrolyte to avoid acid stratification

Chargers and accessories for forklift batteries

In addition to the actual spare parts, the right forklift battery accessories play a central role in operational safety and efficiency.

Typical accessory components:

Aquamatic systems for automatic filling with water
Battery water in canisters for manual refilling
Electrolyte circulation to improve charging efficiency
Chargers in 24 V, 48 V or 80 V – tailored to battery type and charging process

By using high-quality battery accessories , you can avoid filling errors, extend the service life of the traction battery and optimize the charging process – regardless of whether it is a lead-acid battery or a lithium-ion battery .

Conclusion: With the right spare parts, your forklift battery remains ready for use

Replacing battery cells , cables , terminal connectors , or other components is a sensible alternative to a complete overhaul – especially in large fleets or with intensive use. Combined with suitable accessories and regular maintenance, this ensures the long service life of your battery and the reliability of your forklift in daily use.