Forklift batteries are possibly the most critical component of forklifts, both electric and gas or petrol powered as without a charged battery, your forklift isn’t starting. 

For electric forklifts, the battery provides the power necessary for the vehicle to operate properly. In this guide, we will go over the essential aspects of forklift batteries, including their construction, operation, maintenance, and safety considerations.

Construction

Forklift batteries are typically made up of several individual cells, each containing a series of positive and negative plates which are immersed in an electrolyte solution. The electrolyte solution is typically a mixture of sulfuric acid and water, which provides the chemical reaction necessary to produce electrical energy. These cells are arranged in a metal case that’s designed to fit into your forklift truck.

The plates within the cells are made of lead, which is a heavy, dense metal that’s ideal for use in batteries due to its value for power and energy per kilowatt-hour, along with its ability to be easily recycled. 

Operation

When a forklift battery is fully charged, it contains a significant amount of electrical energy, which is used to power the vehicle for extended periods. As the forklift is operated, this electrical energy is gradually used up, and the battery voltage decreases.

When the battery voltage drops to a certain level, the forklift operator will typically need to recharge the battery. This involves connecting the battery to a charger designed to supply the correct voltage and current necessary to recharge the battery back to full charge.

Maintenance

Forklift batteries require regular maintenance to ensure they operate safely and effectively. This can include:

• Regular cleaning to remove dirt and debris from the battery and its terminals
• Monitoring the water level in the cells and topping up with distilled water as necessary
• Checking the battery's voltage and capacity to ensure it is operating correctly
• Inspecting the battery case and terminals for signs of damage or corrosion
• Replacing the battery if it is no longer able to hold a charge or is damaged

Safety Considerations

Forklift batteries can be dangerous if they are not handled correctly. Some critical safety considerations every business should follow are:

• Wearing protective clothing, including gloves and safety glasses, when working with batteries
• Avoiding contact with the electrolyte solution, which is highly corrosive and can cause severe burns
• Never smoking or using an open flame near a forklift battery, as this can ignite the hydrogen gas produced during charging
• Ensuring that the battery is secured correctly in the forklift truck to prevent it from shifting during operation

Regular maintenance and safety precautions are necessary to ensure that forklift batteries are safe and effective and don’t put your vehicle or staff in danger.