An electric forklift is only as good as its battery. Look after the battery properly and you’ll get consistent power, long service life, and fewer breakdowns. Ignore it and problems show up fast: shorter run times, more frequent charging, and unexpected downtime that can disrupt operations. Since forklift batteries are one of the most expensive components in a fleet, investing in good maintenance is a straightforward way to save money and keep workplaces safe. Here are seven expert tips that every business should follow.
Batteries have a limited number of charge cycles, so the way they are charged matters. Lead-acid batteries should be charged once they drop to around 20–30% capacity and then fully recharged. “Topping up” or partial charging shortens their lifespan. Lithium-ion batteries, by contrast, can be opportunity charged without harm, making them better suited to multi-shift operations. Training operators to follow the right charging routine for the battery type prevents early deterioration and ensures forklifts are available when needed.
Leaving batteries on charge for too long is a common mistake. With lead-acid batteries, overcharging generates excessive heat and accelerates wear on internal plates. It also increases water consumption, forcing operators to top up more often. Modern chargers include automatic cut-off features, but only if they are used correctly. Supervisors should make sure staff are trained to connect chargers properly and check that cut-off systems are working. Even lithium-ion batteries, which are more resistant to overcharging, benefit from avoiding unnecessary time on the charger.
Lead-acid batteries require regular watering to stay healthy. Low water levels expose internal plates to air, which causes irreversible damage and reduces capacity. Operators should check fluid levels weekly and top up with distilled water after charging, not before, to avoid overflow. Overfilling is just as damaging as running low, since it can cause leaks and corrosion. Employers should provide clear instructions and the right equipment for safe, accurate watering routines.
Dust, grease, and residue build up over time, creating pathways for electrical discharge and increasing the risk of short circuits. Acid residue from small spills can also corrode terminals and damage the truck. Regular cleaning with appropriate solutions extends battery life and improves safety. This task should be included in scheduled maintenance rather than left until a problem arises. Clean batteries also make inspections easier, since operators can clearly see signs of leaks or cracks.
Batteries are sensitive to extreme temperatures. Excessive heat accelerates chemical reactions, shortening lifespan, while cold conditions reduce performance and charging efficiency. Ideally, charging stations should be located in temperature-controlled areas with good ventilation. Forklifts used in cold storage facilities may need specially designed batteries or insulation to maintain performance. Managers should be aware of the environmental conditions on site and adjust maintenance practices accordingly.
Operators are the first line of defence against battery problems. A simple daily inspection before starting a shift can prevent minor issues from turning into costly failures. Checks should include cable condition, connector tightness, and visible damage such as bulging or cracking. Training staff to recognise warning signs empowers them to act quickly. Employers should also encourage operators to report issues immediately rather than trying to push through a shift with a failing battery.
Even with diligent daily checks, expert servicing is essential. Technicians can test capacity, identify early signs of wear, and ensure charging systems are working properly. They can also carry out repairs or replacements before downtime becomes unavoidable. Businesses that invest in planned servicing reduce emergency breakdowns and extend the overall life of their fleet.
You can find a detailed forklift servicing guide over on our blog that explains what to expect from professional maintenance.
The benefits of proper maintenance go far beyond avoiding breakdowns. Well-maintained batteries deliver longer run times, reducing the need for mid-shift changes. This improves productivity and ensures operators can focus on their tasks instead of worrying about power. Energy efficiency is another advantage. Batteries in good condition charge more effectively, lowering electricity costs across the fleet. Finally, strong maintenance practices support health and safety by preventing hazards such as leaks, fires, or sudden power loss.
Despite clear guidance, certain mistakes appear repeatedly in workplaces. Overcharging or undercharging, neglecting fluid levels, and failing to clean terminals are among the most common. Storing batteries in poorly ventilated areas is another frequent issue, raising risks of gas build-up during charging. Businesses should take time to review these mistakes with staff and build corrective habits into everyday routines. Prevention is always cheaper and safer than fixing damage after it occurs.
Battery care should not be seen as a stand-alone task. It is part of a wider maintenance culture that extends to tyres, hydraulics, and every other forklift component. A well-maintained battery reduces strain on the motor and electrical systems, creating a positive knock-on effect for the whole truck. This is why battery care is often described as protecting the “heart” of a forklift. Treat it well and the entire machine performs better.
Batteries are one of the most valuable assets in any forklift fleet, and the way they are maintained determines how long they last. Charging correctly, avoiding overcharging, keeping fluid levels right, cleaning regularly, monitoring temperature, training operators, and scheduling professional servicing are seven practical steps that deliver real results.
Here at Acclaim Handling, we support businesses with expert servicing and guidance to help them get the best from their fleets. Our trusted technicians for your fleet keep batteries in peak condition with tailored support, helping you to reduce costs, prevent accidents, and ensure your forklifts remain dependable day after day.
01708 861 414
