Did you know that prop & movie sets and museum workers use forklifts? You might use yours for less glamorous, but no less important work, like dock or retail jobs. Either way, you’ll need your forklifts to run efficiently for long durations. How long your forklift lasts depends on its battery – and when it gives out, you’re in trouble. 

Choosing the right battery for forklift operations is vital to its upkeep; it’s what literally makes the machine go. However, you don’t know how to choose the right battery. You don’t know which type is best compatible with your job. There’s plenty to get into regarding battery choice and forklift maintenance. We’re going to discuss:

  • How to tell if you need a replacement battery
  • Types of batteries
  • What to consider when choosing a new battery

Keep reading to learn more about different forklift power solutions and battery replacement tips. 

How to Spot a Dying Forklift Battery

It’s important to spot when your forklift parts are wearing out so they don’t fail at the worst time. One sign your battery is failing is decreased run time. Your machine may run for less and less time on a single charge. A forklift charge should last for eight hours – an average work shift. 

Slow charging is another symptom of a failing battery. Charging a battery can take a single shift (eight hours) or more. For example’s sake, we’ll say the maximum time it takes a battery to charge is eight to ten hours. Your battery may be dying if it requires more time than this to charge. Other signs your forklift battery is dying are: 

  • Corrosion on terminals
    • You see visible build-up on battery terminals
  • Visible damage
    • There are cracks or bulges on the casing
  • Dimmed displays
    • The forklift’s displays are dim and difficult to see
  • Decreased power
    • Your forklift is having a harder time lifting heavy loads or operates at a lower power level
  • Frequent overheating
    • The battery gets excessively (or rapidly) hot when charging or running
  • Acid leaks
    • There’s acid leaking from the casing
  • Sulfuric smell
    • You notice a sulfur-like smell from the battery

Battery Replacement Tips: Performing Forklift Maintenance

You can help maintain sustainable forklift operations by regularly inspecting the battery. Check for signs of damage or corrosion. Keep an eye on your charge times, you may notice that your battery is taking longer to charge. It’s also worth noting that you can overcharge your battery, which can compromise the battery life. 

Consult a professional if you think something is wrong with your battery. You should leave forklift service to the professionals. This will ensure the issue is the battery and not something else. Always follow safety protocols when operating or doing forklift repair work. 

Choosing Your Battery for Forklift Operation

You can choose from three types of batteries for your forklifts. The first is lead-acid batteries, the most common type used in warehouses. They’re commonly used due to their cheapness, reliability, and availability. Lead-acid batteries work best in medium to heavy-load applications. 

Lead-acid batteries can be recharged multiple times and are great for forklift energy efficiency. They’re also easy to maintain but they have disadvantages. Lead-acid batteries are easy to maintain, but they need plenty of it. Here’s a quick aside: lead-acid batteries are also called “wet-cell batteries,” and require regular watering. Maintenance includes:

  • Checking water levels
    • Too low or high water levels can compromise the battery
  • Equalizing charges
    • Essentially overcharging the battery to remove sulfate crystals that reduce battery efficiency
  • Cleaning battery terminals
    • Removes corrosion which blocks electrical flow to and from the battery

Lead-acid batteries are great forklift power solutions for people looking for an inexpensive and reliable power source. 

Lithium-Ion Batteries

Lithium-ion batteries are popular due to their longer operation times, faster charging cycles, and greater energy efficiency. They are also maintenance-free and can help you reduce costs and downtime.

These batteries have a significantly longer lifespan and can provide consistent power throughout their lifecycles. You can recharge a lithium-ion battery whenever needed without damaging it. The greatest disadvantage of these batteries is their upfront cost. 

You’ll spend a lot of money purchasing lithium-ion battery replacements for your forklift fleet. However, you may find that the long-term benefits may outweigh the expense. 

Gel Batteries

Gel or valve-regulated lead-acid (VRLA) batteries are another common choice. These batteries use gel electrolyte instead of liquid acid, meaning they’re maintenance-free. Gel batteries don’t leak or emit gasses, making them perfect for indoor and food-related tasks. They’re also shock and vibration-resistant. 

A gel battery’s slower charge time and lower capacity may not make it the bestchoice foroperations requiring expediency. 

Choosing Forklift Parts: How to Pick the Right Battery

Picking the right battery for your forklift repair depends on various factors. Below is a list of what you should consider before choosing batteries: 

  • Operating hours
  • Workload
  • Maintenance needs
  • Charging time
  • Overall cost

Many workplaces commonly prefer lithium-ion batteries because they charge fast, last long, and don’t require much upkeep. They’re great for multi-shift operations because you can charge multiple times between shifts. 

Gel batteries are preferred when safety is paramount, like when working with food or in low-ventilated areas. Lead-acid batteries are best if you don’t want to spend much upfront, and they’re ideal for short-shift work. You should consult your forklift dealer or manufacturer to ensure you choose the right battery.

Finding a Reputable Forklift Parts Dealer

Industrial battery maintenance can be a chore, but it doesn’t have to be. You can rest easy because Superior Industrial Products will make finding the right battery for forklift operations easier.

Our professional, multi-state team of certified specialists has all the know-how you’ll need to stay on top of forklift maintenance. Our vast resources and expertise make us the largest independent forklift repair company in Tennessee, Indianapolis, and Ft. Worth, TX. Here are some of the parts we offer our clients: 

  • Alternators
  • Air filters
  • Batteries
  • Carburetors
  • Drive motors
  • Engines

Contact us today and make Superior Industrial Products your go-to shop for forklift sales and repairs!