Basics of Forklift Battery


The forklift battery generally has two functions:

The primary ability is to give a force source to the forklift.

The second, and lesser referred to work, is to give mass as a stabilizer, which helps the forklift’s lifting limit.

1. Components

Battery case

The battery case houses the battery’s individual cells. The quantity of cells can go from six to 36, contingent upon the voltage. Voltage is normally 12, 24, 36 or 48 volts.

Battery cells

The battery cells are basically little, independent individual batteries comprised of a progression of firmly stacked lead plates loaded up with sulfuric acid.

Battery bars

The battery bars are enormous lead bars that interface the individual cells, making a total circuit.

Battery cables

These cables can change in size from 4-gauge wire, which is generally the distance across of a pen, as far as possible up to 4/0 cable that can be in excess of an inch in measurement. Strong wiring is needed to deal with the high amperage a few batteries can create. A few batteries can have an amp hour rating of as much as 1,200 amps.


There are usually two kinds of batteries for commercial forklifts:

lead-acid battery

Lead acid batteries are the most widely familiar in the forklift market. They are occasionally alluded to as wet cell batteries. Combination parts incorporate a battery case, cells, and cables, also a combination of sulfuric acid and water.

Lead acid batteries need periodic upkeep for top execution. Some charging frameworks may require particular electrical work to help voltage requests. Wet cell batteries additionally need customary watering to keep up electrolyte levels. Organizations should purchase specific watering frameworks to guarantee levels are exact. With the correct upkeep, most lead acid forklift batteries last as long as five years or more.

lithium-ion battery

Lithium-ion batteries are filling in ubiquity for forklift application. While more costly than wet-cell batteries, they offer numerous advantages in correlation. They are sans upkeep, need no watering, and diminish potential dangers to laborers. Lithium-ion batteries additionally can be snappy charged and have no overcharge hazard. These advantages all mean users spend less energy keeping up forklift batteries.

Lithium-ion batteries can be cost-restrictive for certain companies. They are additionally lesser, requiring additional forklift stabilizers in the battery compartment. Lithium-ions can likewise endure harm at high temperatures or in the event that they are put away with a full charge.

Also other power choices can be chosen for forklifts, for example, propane, diesel or gas power. However, by far most of business forklifts use either lead-acid, lithium-ion products.

The technology of these industrial batteries varied wildly. As a result, differently affects forklift effectiveness.

Note that lead-acid batteries take around 8 hours to charge, and afterward require an additional 8 hours for a cooling period. Classically, one lead-acid battery can just power a forklift for one move.

Lithium-ion batteries, then again, just take 1 to 2 hours to charge and don’t need a chilling off period. One lithium-ion battery can control one forklift several times.

3.How to Keep the Capacity

Both lithium-ion batteries and their lead-acid partners should be maintained appropriately in order to maximize the value of their work. Their operation life will decrease if proper electric forklift battery care isn’t completed as it should be.

To augment operation life and in general battery limit, certain measures should be taken for clients of both battery types. However, lead-acid batteries require more consideration and consideration contrasted with lithium-ion.

Lead-acid forklift batteries require:

Cell Balancing

Traditional technology like this prompts a continuous state where the acid and water inside become defined (isolated on a level plane with the acid more focused nearer to the base). This state structures sulfate precious stones towards the lower part of the cells and debilitate their capacity to hold a charge. Balancing will separate the sulfate precious stones however on the off chance that the battery has been disregarded for a really long time the crystals won’t break.

Temperature Control

Lead-acid batteries should be kept inside a specific temperature range, or probably they will have a more limited working life. What’s more, they likewise get exceptionally hot while charging, which expects them to be charged and put away in a temperature-controlled space.

Liquid Level Management

Equipment related to liquids must be checked to guarantee they have enough water about once every 10 or so charging cycles.

Lithium-ion batteries are considerably less destitute with regards to electric forklift battery care, as they even out consequently, work well in a lot higher temperatures (making temperature generally a non-issue), and don’t need any liquid level administration.

4.Battery Safety

Periodical maintain is necessary for lead acid batteries, and it can significantly build their service life. Essential battery review and upkeep ought to incorporate watering, testing for damaged cells, searching for indications of spilling and dissipation, checking the terminals and links for consumption, and intermittent cleaning of acidic buildup from the battery case.

Battery cell water levels should be kept up about at about a half inch beneath the vent cap openings and just refined or deionized water should be utilized. Water should just be added after a charge cycle.

For security, any fixes should be finished by a certified professional. They have the apparatuses, the parts and the investigating capacities to deal with more intricate battery administration issues.

Potential battery safety issues contain the accompanying:

Out Gassing

Close to the furthest limit of the charging cycle batteries may begin delivering hydrogen gas. This gas is unstable and care should be taken to confine charging batteries from warmth or fire sources.

Charging zones should be enough ventilated and battery covers ought to likewise be opened during charging so that gasses can vent.

Drop Hazard

Some forklift batteries can be more heavy than you can imagine, it should be extra careful when removing and replacing.

A lifting bar or comparative kind of gear should consistently be utilized while removing batteries. Forklifts ought to likewise be appropriately situated while a battery is removed or replaced.

Destructive Chemicals

The majority of forklift batteries use sulfuric acid. Anyone should be wary about sprinkling acid on their skin, getting it in the eyes or any close to home contact with the synthetic when using the batteries.

The users should wear defensive stuff, for example, well-being goggles, face shields, gloves, long sleeves and covers when working with batteries. When topping off, acid should consistently be filled water, never water into acid.

On the off chance that acid gets spilled, it should be killed with a combination of baking soda and water. Subsequent to applying the baking soda blend to the acid spill, the acid is killed once bubbling stops. Cleanup can be taken care of utilizing a permeable material like soil.

Electrical Short

In certain circumstances, contact with battery cells can cause a short out, which can cause consumes and different harm.

Users should eliminate any metallic adornments and abstain from utilizing metal apparatuses when working straightforwardly on batteries.

5.How Much is A Forklift Battery

Forklift batteries cost somewhere in the range of $2,000 and $6,000 relying upon specs and size.

While choosing a battery, consider these questions first:

What is the forklift voltage or number of cells in the battery?

Does the forklift require an EE or EX battery?

What is the compartment size of the forklift?

Is the forklift compartment covered or does the battery require a cover?

What sort of charging connector is utilized on the forklift?

What position on the battery do you wish the battery cables to move on the plate?

6.What is a Forklift Battery Charger?

The role of industrial charger is to charge the forklift battery as fast as conceivable without shortening the battery’s life expectancy because of overheating and overcharging. Before the improvement of modern forklift battery chargers, people manually set the required voltage and amperes to charge the battery, consequently some man-made errors and battery damage occurred. The present industrial charger contains an intricate organization of cards and sensors that avoid mistakes that people make. Nowadays, chargers have preset boundaries that shield the battery from overcharging and harm. These preset boundaries will really quit charging and show mistake codes if there is an issue with the battery as opposed to keep charging until it either boils, or even leads to the worst result of a fire.

There are a good many of options concerning industrial chargers from compact portable charger that is suitable for any wall outlet, to huge divider mounted units that require huge amperage capacities. Current chargers permit the client to custom tune a particular charge cycle. This customization permits you to control everything from the measure of voltage, amperage, charging time, and even the fill rate over a given period of time. These controls permit you more noteworthy adaptability in charging, just as longer battery life and execution.

7.How to Charge the Forklift Battery

Timely Charging

At the point when your forklift’s battery hits the red zone (just 20% charge remaining) cease utilizing that battery immediately. Proceeding to utilize a battery past 20% contrarily influences its life expectancy. Additionally, profound releasing can make electrical segments overheat and harm your forklift.

Continuously Allow Your Battery to Charge Completely

A battery has a set number of charges in it, around 1,500, and doesn’t recognize half-charging or full charging. Only partially charging the battery will drain the battery pack.

Evade Extreme Temperatures

Battery life can be decreased by as much as 50% once the surrounding temperature arrives at 92 degrees. At the opposite finish of the range, battery execution drops 30% when the temperature arrives at 30 degrees. In the event that your forklift works in outrageous temperatures, select the batteries which are produced for these situations.

Don’t Charge the Battery at Will

The best opportunity to charge the forklift battery is usually 20-30% left. If charge a battery with 50% to 60% of its remaining electricity quantity, it will directly waste 20% – 30% of the original power. Try to charge after a complete service cycle.

When you need to purchase a large number of forklift batteries, consider some reasonable questions and requirements first, for example, how long will a forklift battery last? How to maintain the battery properly?

Many factors work. Especially lithium-ion batteries, which are changing the material dealing with industry on account of their expanded productivity and low upkeep. Regardless of which type you use in your forklift, notwithstanding, it’s basic to appropriately charge, store and keep up your forklift batteries to amplify their life expectancy – and value.

Share now

Leave a Reply

Your email address will not be published.