If your forklift battery is completely empty, your industrial truck will stop operating – and with it important work processes.
However, deep discharge can not only lead to annoying downtimes, but can also damage the battery in the long run.
In this article, you'll learn how to get your forklift battery back in shape after a deep discharge, what options there are for cell replacement , and when a used battery might be the better alternative.
Causes of deep discharge
Deep discharge occurs when the battery is discharged below its minimum voltage. Common causes include:
- Excessive operating times without recharging in between
- Incorrect charging behavior , such as charging with too low a charging voltage
- Defective chargers or damaged charging cables
- High ambient temperatures that reduce capacity
Avoid future deep discharges by maintaining charging intervals and regularly servicing chargers.
First aid for a deeply discharged battery
- Safety first: Wear appropriate protective equipment (gloves, safety goggles) and ensure good ventilation.
- Check the battery: Measure the voltage of each cell. If it's below 1.8 V, there's an acute risk of lead sulfate crystallization.
- Slow charging: Start with a gentle current (C/20) until the cell voltage reaches at least 2 V.
- Full charge with C5 test: After the basic charge, we recommend a full C5 capacity test to determine the true remaining capacity.
Tip: Modern chargers with a trickle charge function prevent deep discharge and significantly extend the life of your battery. Learn more about properly charging forklift batteries here.
Buying new battery cells: When and how?
If only individual cells in your forklift battery are damaged , it's often worth replacing them rather than buying a completely new one. Here's how to proceed:
- Determine cell type: Look at the labeling (e.g. 2PZS160 or 5PZS400 ).
- Order suitable cells: We offer new battery cells in all common voltages (2–10 V per cell).
- Installation & Balancing: After replacement, charge all cells evenly to avoid charging imbalances.
By purchasing additional cells, you can save up to 50% of the cost of a new battery and protect the environment.
Alternative: Used battery as a complete solution
If your battery is severely worn or several cells have completely failed, a used forklift battery can be an economical alternative:
- C5-tested capacity : You will only receive capacity-tested batteries.
- Immediately available: From stock, often available for delivery within a few days.
- Cost savings: Up to 50% cheaper than new forklift batteries .
Prevention: How to prevent deep discharge
- Regular intermediate charging: Recharge briefly during breaks or shift changes.
- Maintain maintenance intervals: Carry out a full charge and capacity test every 3–6 months.
- Adjust chargers: Have the voltage and current checked according to the manufacturer's specifications.
- Battery monitoring: Smart systems display charge level and temperature in real time.
Conclusion
A deeply discharged forklift battery can often be revived with proper charging or by replacing individual cells. If the battery is severely worn, we recommend switching to a used battery to minimize downtime and costs. Regular maintenance and modern chargers protect your investment from further deep discharge in the long term.
