Forklift batteries are the heart of every electric forklift. Their functionality is essential , because without a powerful battery, operations come to a standstill. However, many underestimate the importance of proper maintenance. Those who treat their lead-acid batteries well can significantly extend their lifespan and reduce costs . In this article, you'll learn which maintenance routines are truly crucial, how to avoid common mistakes, and what to consider when charging, refilling, and checking .
Why proper care is crucial
Most lead-acid batteries in forklifts are among the most widely used battery systems , achieving approximately 1,200 charge cycles . However, incorrect charging, deep discharge , or lack of maintenance can drastically reduce this number. If a forklift battery is not properly maintained, the following can occur:
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Sulfation , which reduces the charging capacity
(Learn more about desulfation here) - Overheating , which results in heat generation
- Loss of capacity because the number of remaining charging cycles decreases
With good care, the life expectancy of a battery can be dramatically increased – and that means lower costs and fewer failures .
Charging correctly: The key to a long battery life
An incorrect charging cycle can significantly shorten the battery's lifespan. Therefore, please follow these practical tips :
- Only charge the forklift battery when the charge level reaches 20 percent – short intermediate charges should be avoided as they reduce the number of charging cycles.
- Always fully charge the battery – a remaining charge of only 50% does not mean the battery is ready for the next shift.
- Avoid deep discharges – a battery should never drop to 20 percent or less , as this will severely affect its capacity.
- Fully charge at night – this way you will have a fully charged battery the next day, sufficient for the entire shift.
- Choose the right charger – it should meet the requirements of DIN 43530-4 to ensure safe charging.
Important: Charging generates heat ! An overheated battery can heat up considerably inside the battery cells . Therefore, it should be charged in a well-ventilated area to minimize heat buildup .
Check electrolyte and water levels regularly
To ensure the battery functions efficiently, distilled water must be refilled regularly. The following applies:
- Always check the water level – too little water leads to sulfation , too much can dilute the electrolyte.
- Only add distilled water after the battery is fully charged – otherwise there is a risk of the liquid overflowing.
- Pay attention to the markings – the water level should always remain in the optimal range.
- Do not use tap water! It contains minerals that can cause deposits and damage the battery.
During charging, the electrical current breaks down into gases such as hydrogen and oxygen . If the water level isn't checked in a timely manner, sulfate deposits can reduce battery performance.
Avoid overheating – safety first
Heat is one of the biggest enemies of a forklift battery. An overheated engine or a very hot battery can significantly shorten its lifespan .
Tips to avoid overheating
- Avoid overheating the forklift – if the engine heats up noticeably , a short break will help.
- Do not start charging immediately after use – a hot battery should cool down first.
- Ensure good ventilation – this reduces the temperature inside the battery .
Excessive heat buildup will shorten the number of remaining charge cycles and may cause permanent damage.
Establish proper care as a routine
Regular maintenance and inspection are essential to keep the battery operational for as long as possible. This includes:
- Check the battery regularly – the water level, electrolyte and charge levels should be checked.
- Always connect the charger correctly – only use a charger that is compatible with the battery.
- Keep your environment clean – dirt and dust can get into the battery and impair its functionality .
- Refill in good time – this prevents sulfation and ensures consistent performance.
Regardless of the length of the charging process, it is important to only connect the battery to the charger when a full charge is possible.
Conclusion: Longer lifespan, lower costs
A well-maintained forklift battery is more powerful, longer-lasting, and more cost-effective . Proper charging, topping, and checking routines ensure that the battery doesn't lose capacity prematurely.
If you take the right measures , you can significantly extend the life of the battery and ensure smooth operation – just as HK Handels GmbH would like to see.
