When to Replace a Forklift Battery

A forklift battery does not usually fail all at once. Most batteries show warning signs before replacement becomes urgent.  Forklift batteries don’t die alone – they take other components with them.  An indicator can often be intermittent drive operation of the forklift or increased failures of electrical controllers, motors, and switches.

One of the most common signs is reduced run time. If a battery used to last most of a shift but now needs charging much earlier, it may be losing capacity. Other signs include slow lift performance, excessive heat during charging, strong odor, visible case damage, leaking electrolyte, or corroded cables.

Heat and Time kill batteries (see FAQ | Forklift Battery Watering).  A well-maintained battery in a light-duty application may last longer than a poorly maintained battery in a heavy-use operation. Poor watering habits, Opportunity or Rapid charging, incorrect charger settings, and deep discharges can all shorten battery life.

Before replacing the battery, it is helpful to inspect the charger, cables, connector, watering history, and application. Sometimes poor performance is caused by a charging problem rather than the battery itself.

Specialty Industrial Battery has developed a Field Inspection Form that can easily be completed by an in-house maintenance department or qualified forklift technician.  Follow this link to begin the process of testing your battery to see if a replacement battery is due.  As you complete the inspection, a report is generated and emailed back to you for your records or replacement justification process.

If the battery is older, losing run time, or creating downtime, a correct replacement battery is a great investment in repowering your forklift. 

Quick takeaway: Replace a forklift battery when it can no longer support the truck's required run time, safety, or reliability--especially after charging and maintenance issues have been ruled out.