The Forklift Battery Maintenance Tips EVERY Owner Needs
When it comes to electric forklifts, battery performance can make or break your entire operation. If batteries aren’t properly taken care of, then they’ll have shorter lifespans and runtimes, and your forklift may experience lower lifting capacities, slower speeds, and increased downtime. The best thing an owner or manager can do is stick to a consistent forklift battery maintenance routine. In this article, we’re going to cover what that routine should include:
- Perform regular forklift battery inspections
- Check electrolyte levels daily
- Clean forklift batteries to prevent corrosion
- Closely monitor battery temperature
- Conduct capacity discharge testing
- Equalize the charge
- Document and track all forklift battery service activities
1. Perform regular forklift battery inspections
If you want to catch small issues before they turn into big, expensive problems, then you have to inspect your forklift batteries at least weekly if not daily. It should include a visual check of the exterior and connection points, cleanliness, fluid levels, and charging status. Here are some key things to watch out for:
- Cracked or swollen battery cases
- Corroded or loose terminals
- Frayed or damaged cables
- Electrolyte leaks or acid residue
- Abnormal water levels
- If the battery is overcharged or undercharged
If you do notice any issues, it’s important to notify a supervisor and not operate the forklift until they are resolved. We also recommend keeping an inspection log to help identify reoccurring problems.
2. Check electrolyte levels daily
It’s crucial to look at your battery’s electrolyte before beginning each shift and replace water lost due to evaporation. Never allow electrolyte levels to drop below the separator protectors, and do not overfill the cells. Overfilling causes loss of acid, reduces battery capacity, and results in corrosion of the steel tray. Here are some watering tips for your forklift batteries:
- Batteries should only be topped off after a full charge; never top it off before a charge
- Fill to 1/8” below the bottom of the vent well to avoid overfilling
- Only use distilled water when filling your batteries
For busy warehouses and material handling operations, we suggest using a single point watering system to ensure consistency and proper filling.
3. Clean forklift batteries to prevent corrosion
Battery cleaning is an especially important part of forklift battery maintenance, because corrosion build up can eventually make contact with the chassis and short out certain components. A monthly cleaning routine helps avoid performance issues and contributes to a safer work environment. Here’s how to handle forklift battery cleaning:
- Use a battery cleaning or neutralizing agent (like baking soda and water) to wash the surface
- Wipe down terminals and cases
- Rinse with water and dry thoroughly
- Always wear PPE when cleaning
4. Closely monitor battery temperature
The temperature of your forklift batteries can significantly affect performance and lifespan. High heat leads to water loss and increased internal resistance, while cold temperatures can slow chemical reactions and hinder performance. You can use a laser thermometer, or other visual indicators, to monitor your battery’s temperature.
- Most forklift batteries are designed to operate optimally between 60° and 110° Fahrenheit
- Install temperature sensors on high use batteries
- Never charge a hot battery; if the battery gets hot during usage or charging, contact JIT Toyota-Lift immediately to inspect it
5. Conduct capacity discharge testing
A critical part of forklift battery maintenance is regular capacity discharge testing. This test measures the battery’s ability to hold a charge and deliver adequate power under a simulated workload. It can help you identify:
- Weak cells
- Faulty intercell connectors
- Reduced capacity before a failure occurs
- Whether forklift battery replacement is necessary
We recommend annual capacity testing by a qualified technician as part of your forklift battery maintenance routine.
6. Equalize the charge
In order to ensure your forklift battery lasts as long as possible, we recommend equalize charging about once a week. During normal operation, different cells within the battery will discharge to varying levels, leading to imbalances. An equalization charge corrects the imbalances by slowly charging the battery at a low rate and bringing all the cells to more equal energy levels.
- Complete an equalization charge every five to ten recharges
- A proper equalization charge will extend the charging period by about three hours
- Incorrect discharging, charging, and maintenance can increase charge imbalances and make equalization even more important
7. Document and track all forklift battery service activities
Tracking inspections, watering, cleaning, usage hours, and charging data helps create a sense of accountability and will assist owners or managers with spotting trends that may indicate deeper issues. Organized records of forklift battery maintenance efforts will support proactive decision making and minimize the chances of unexpected failures. Lead acid battery maintenance is extensive and time consuming, but it will result in a longer lasting battery.
At JIT Toyota-Lift, we help you protect your battery investment. We provide expert service and maintenance, testing, single point watering, cell replacement, complete forklift battery replacement, charger repairs, and more. Plus, we have a mobile wash bay, so we can handle battery cleaning at your facility.