Replacing a forklift battery is one of the regular maintenance tasks for electrically powered industrial trucks.
Whether due to natural aging, technical defects or as part of a shift change – the replacement should always be carried out properly, safely and with the right tools.
In this article, you will learn where the battery is located in common models , how to change it , and what you should pay particular attention to in order to avoid damage or safety risks.
Where is the battery located in the forklift?
In most electric forklifts, the battery is located centrally in the vehicle frame—typically under the driver's seat or in a hinged battery cover. The exact location depends on the manufacturer and model.
Example: Linde electric forklift
On Linde forklifts (e.g., E14–E35 series), the battery is usually located under the driver's seat. Depending on the model, the seat can be easily folded open or swung to the side. Some models feature side-mounted battery removal—this is particularly useful for multi-shift operation with removable batteries.
Tip: The forklift operator's manual contains precise information on battery accessibility and the prescribed removal method.
Preparation
What you need to consider before changing the battery
Before you start the actual battery replacement, you should ensure the following points:
- Switch off the forklift and secure it against rolling away
- Wear personal protective equipment (e.g. gloves, safety goggles)
- Disconnect the charger and measure the voltage if necessary
- Provide tools and lifting aids if necessary
- Suitable location with stable ground and ventilation
Caution: When handling lead-acid batteries, there is a risk of burns and explosion. Open flames and sparks must be avoided at all costs.
Step-by-step instructions: Changing a forklift battery safely
Gain access to the battery
Fold or unlock the seat or cover to fully expose the battery.
Turn off the main switch (battery isolator)
If present, disconnect the battery using the main switch before disconnecting.
Disconnect battery connector
Carefully disconnect the connector from the battery cable. Caution: Do not apply any tension to the cable.
Remove the terminal cover and disconnect the connections
Disconnect the negative terminal first, then the positive terminal . This will prevent accidental short circuits.
Lift out the battery
Use a suitable lifting or crane arm with a battery beam. Ensure horizontal lifting and secure grip of the attachment points.
Insert new battery
Place the new or reconditioned battery exactly where it was intended. Do not tilt or tilt it.
Install connections in reverse order
Connect the positive terminal first, then the negative terminal . Then connect the plugs and reattach the terminal covers.
Secure the battery and close the seat/cover
Perform functional test
Start the forklift and check that the voltage is correct and that no error message appears.
Special instructions for lithium-ion batteries
Different requirements apply to lithium-ion systems:
- No gas development, therefore usually other ventilation solutions
- Electronic monitoring via a BMS (Battery Management System)
- Plugs and interfaces vary depending on the manufacturer
- Replacement only recommended by trained personnel
When does it make sense to change the battery?
A complete replacement of the forklift battery is advisable in the following cases:
- The battery no longer reaches the required capacity
- Recurring error messages or loading problems occur
- The forklift regularly fails under load
- The battery can no longer be regenerated
As an alternative to purchasing new batteries , HK Handels GmbH also offers tested, regenerated forklift batteries – an economical and sustainable solution.
Conclusion: Changing the battery correctly means avoiding downtime
Correctly replacing a forklift battery requires technical understanding, appropriate tools, and a sense of safety. A structured approach and careful attention to the steps can minimize downtime and maximize the lifespan of the battery technology. If you're unsure or have a larger fleet, we recommend consulting a specialist company.
HK Handels GmbH not only offers you high-quality batteries, but also a comprehensive on-site service for capacity testing , regeneration and professional replacement.
