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When you replace your forklift battery, it’s imperative you choose one with the right dimensions. Having the model information and dimensions of the battery will make it easy for you to find a new or refurbished battery. Follow this quick guide to choosing the right size forklift battery to make the process even easier. With those details in hand, you can see our available battery models and match the right size to your lift truck.

1. Measure the Compartment and the Battery

Ensure your forklift battery will fit by measuring the compartment rather than the dead battery. Record the width, depth, and height in inches.

While you might replace your dead battery with the exact same model, replacing it with a refurbished battery might lead to a slightly different size. As long as it fits into the compartment, provides the right counterweight, and is the right voltage, the replacement battery will be the right size.

2. Confirm Your Voltage

It’s crucial to choose the right voltage; therefore, you need to know what voltage your forklift requires. Keep in mind each cell of the battery provides two volts, so a battery with 12 cells produces 24 volts.

Smaller forklifts that do light work can run on 24V batteries, but the larger the lift truck or the more it lifts, the more power it requires.

3. Check the Counterweight Requirement

The next point in this quick guide to choosing the right size forklift battery is to check the minimum battery weight requirement. The battery acts as a counterweight, and to safely operate the machine you need to choose the right weight. You can check the forklift’s data plate for this number.

Lead-acid batteries are heavier than lithium-ion batteries, and batteries with higher voltages generally weigh more than batteries with lower voltages. Installing an underweight battery can create dangerous stability problems.

4. Gather Information About Connectors

Measure the length of the cable, but be sure to only check the length that hangs out from the battery tray. Also note where the battery plugs into the truck, such as on the driver’s left side.

Connectors are color-coded and will not connect with connectors of a different color. Standard plug colors include gray, red, yellow, blue, green, and orange. Note the color of the plug and the size.

When it’s time to replace your forklift battery, contact Green Power Forklift Batteries. We offer new and refurbished electric forklift batteries for sale. If you’re not sure which forklift battery you need, contact us so we can help.

Inspecting your forklift every day helps ensure its performance and the safety of operators and other workers. OSHA requires forklift operators to examine the machines at least once daily and after each shift if used throughout the day. If the operator finds a problem with the equipment, they report it to the supervisor.

If there’s an issue with the forklift battery, an experienced Green Power Forklift Batteries technician can use a six-stage process to clean, analyze, and diagnose the problem. Read about our forklift battery inspections and what to expect.

Initial Inspection

Visual Inspection

Just as the forklift operator begins a routine pre-operation inspection with a visual assessment, an expert technician begins analysis with a visual exam. We check for symptoms of acid loss, automatic watering systems, corrosion, inter-cell connector problems, signs of explosions, and physical damage.

Wash and Neutralization

After the visual inspection, we wash the battery with water and acid neutralization chemicals. This creates a clean and safe environment.

Inter-Cell Resistance Monitoring

High inter-cell resistance causes voltage to drop and leads to excessive heat. We look for loose screws and corroded IC connectors, sulfated and corroded connections, bad welds, and bad cables. If we find problems, we correct them.

Diagnostic Testing

Pre-Load Test Charge

After looking over the battery and cleaning it, the next step you can expect in the forklift battery inspection is the diagnostic test. Before we perform the diagnosis load test, we give the battery a full charge. This ensures the accuracy of the test results.

Diagnosis Load Test

During the test, we measure all the cells’ open-circuit voltage (OCV) and specific-gravity (SPGR). Through this test, we learn the battery’s amp-hour (Ah) capacity. We analyze the test results to determine our recommendations for what to do with the battery.

After the Test

Post-Load Test Charge

Once we’ve completed our inspection, we fully charge the battery. This completes the process, and we return the battery to you and give you our next-step recommendations. In some cases, this six-step inspection process corrects issues with batteries. If the diagnosis load test reveals problems with the battery’s capacity, we might suggest a more detailed service.

Green Power Forklift Batteries follows an 18-step reconditioning process that makes us a leader in forklift battery sales. Whether you want a new or reconditioned forklift battery, check out our supply of high-quality batteries today.

A lead-acid battery’s power comes from the chemical reaction taking place in each battery cell. Connecting the cells in a series creates the battery’s total voltage.

Better understand the components of your forklift battery with this overview of forklift battery cell arrangements.

Cell Arrangement

Each battery cell contains a set of positive and negative plates, also called electrodes, immersed in an electrolyte. The positive plate is lead dioxide (PbO₂), the negative plate is sponge lead (Pb), and the electrolyte is a diluted sulfuric acid solution (H₂SO₄). The nominal voltage per cell is 2 volts.

The usual cell arrangement for a 12-volt forklift battery contains six cells in a single row. A 24-volt battery has 12 cells in either two rows of six cells or three rows of four cells, while a 32-volt battery has 16 cells arranged in four rows of four cells each. A 36-volt battery has 18 cells arranged in three rows of six cells. Once you know your battery’s voltage and arrangement, view the forklift battery models we offer to match the right configuration to your equipment.

Intercell Connectors

Forklift battery cells are arranged in a series, connected so that each cell can contribute to the total overall voltage of the battery. The positive terminal of one cell is next to the negative terminal of the next cell. The cells are connected by intercell connectors, which are generally lead-coated copper straps or solid lead. The connectors keep the cells together during storage and use.

If the intercell connectors loosen, the electrical resistance between the cells increases—increased electrical resistance raises the temperature in the battery. It’s important to keep intercell connectors tightened to avoid battery failure or damaging equipment that runs on the battery. Test the battery intercell connection resistance periodically to avoid problems.

How To Identify Your Battery

Your essential forklift battery information is either stamped onto an intercell connector or stamped onto a nameplate affixed to the tray. The information generally includes the model number, forklift battery capacity, battery voltage, and serial number. Use this information to maintain, service, and replace your battery.

If you need to replace your battery, Green Power Forklift Batteries can help you save on costs. Our refurbished forklift batteries retain 85 percent of the rated capacity for brand-new forklift batteries, making these batteries an excellent, durable option for your forklift power needs. Shop with us today.

If you rely on a forklift to load, unload, and transport goods, you can’t afford problems with your forklift battery. Battery issues can damage your forklift, cause declining performance, or take a forklift out of commission.

Keep your facility operating efficiently with a new forklift battery. Read this brief guide to replacing your forklift battery so that you can make informed decisions.With the manufacturer name and model number, we can give you information about compatible batteries.

Know the Signs It’s Time To Replace

Most forklift batteries last for up to 1,500 charging cycles before they stop charging to full. Fast-charging batteries have shorter lifespans. If your freshly charged battery only functions a few hours before needing to be recharged, it might be time to replace it.

Old or malfunctioning batteries can also cause forklifts to stall or run slowly. If the operator notices this, they should immediately stop driving the forklift and notify a supervisor.

If you see corrosion buildup on the battery case, you should replace it. Likewise, if you see the battery emit smoke while it’s charging or in use, immediately stop using that battery and get a replacement. And if your battery smells sulfurous, like rotten eggs, replace it. If you need your forklift battery inspected, contact us for cleaning, analysis, and diagnosis.

Buy the Battery

Once you see signs it’s time to replace your forklift battery, the next step to buy a replacement from a reputable source. With the manufacturer name and model number, we can give you information about compatible batteries. You can also browse the battery models we carry to find a compatible replacement for your electric forklift.

Choose between a reconditioned battery or a brand new one. Our reconditioned batteries carry an impressive 85 percent minimum charge capacity of brand-new forklift batteries. And our brand-new forklift batteries come with a seven-year warranty.

If you need to select a new charger, make sure you get one with the right amp hour (Ah) rating for your new battery. An incompatible battery could lead to a buildup in sulfate crystals, which is the number one cause of early battery failure in lead-acid batteries.

Maintain Your New Battery

Follow your manufacturer’s recommendations to properly maintain your new battery. This typically involves giving the battery distilled water after it has been fully charged and cleaning the top of the battery every month to remove buildup.

Visually inspect the battery’s cables and connectors regularly. If you find breaks, cracks, cuts, or kinks, get someone to service your battery to fix problems and keep the battery safe for operational use.

Contact Green Power Forklift Batteries

If you need new forklift batteries, choose Green Power Forklift Batteries. We’re committed to providing reliable power solutions, and we sell forklift batteries and accessories to keep your facility moving along. Contact us today to find your battery replacement.

Almost every modern warehouse uses forklifts. This means that when your forklift isn’t working properly, it can severely affect the efficiency of your business.

Luckily, there are plenty of easy solutions for solving common forklift battery problems. Here is a quick guide to troubleshooting your forklift battery.

Try Charging It One More Time

If the battery is non-functional when you start the forklift, you might you broke the battery. However, it could also simply be out of charge.

There might be some internal problems in your forklift, but usually if your forklift won’t start, it’s because the battery isn’t charged. You should try to charge it one more time to rule out a dead battery as the source of your trouble.

Make Sure There’s Enough Water

Forklift batteries require a certain level of distilled water in order to function to their fullest capability. When the level of distilled water gets too low, it causes the battery to overheat due to an electrolyte imbalance, which destroys the battery.

Before checking the water level, wait for the battery’s temperature to cool down so that it’s safe to touch. Then, add enough water to get it to the proper level, and be sure to create a routine to check the water level more often.

Clean Off the Contact Points

Another common issue that reduces the efficacy of a forklift battery is when the contact points get corroded or dirty. When this happens, it prevents the cables from transmitting electricity through the circuit.

All you need to do is use a battery cleaner to wipe off the residue surrounding the contact points. However, don’t use a wire brush to wipe it off because this will cause sparks to fly. In addition, you will want to make sure that your battery is completely disconnected before you clean it to prevent yourself from getting electrocuted.

Inspect Your Cables and Connections

Sometimes, the cables in a forklift battery can come loose while the forklift is operating because the connections weren’t tight enough. If the connections aren’t firm between your cables and contact points, the forklift battery won’t create a full circuit, so the electricity won’t flow properly.

Thankfully, this is a quick fix because all you must do is tighten the connections and restart the forklift.

Overall, you will have a tough time getting around on your forklift without a forklift battery. After reading through a quick guide to troubleshooting your forklift battery, you shouldn’t be stranded for too much longer. Also, make sure to reach out to a reliable source if you need a replacement forklift battery.

Forklifts require routine maintenance in order to serve as the backbone of your warehouse operations. Some of these maintenance activities revolve around the battery.

In addition to charging your forklift battery, you also must replace it from time to time, which begs the question of whether it’s better to purchase a new or reconditioned battery? Here are the advantages of reconditioned forklift batteries.

They Are Cheaper

Reconditioned forklift batteries are much more affordable than brand new ones. The money saved from switching to reconditioned batteries will lead to significant savings over time. This leaves you extra room in your budget if a disaster occurs or you need to restock other gear.

Cost-cutting measures in warehouses often come at the expense of work quality. However, if you save money by looking at reconditioned forklift batteries for sale, you don’t have to settle for a lower-quality product.

Reconditioned Batteries Are High-Quality

Although you might think that reconditioned batteries are low-quality, they are comparable to brand new batteries if they’re serviced properly. Battery companies will go through several checks to ensure that their reconditioned batteries are high-quality, such as cleaning, desulfation, and charging.

After the manufacturer completes their final tests, you might struggle to tell the difference between a new battery and a reconditioned one. Therefore, reconditioned forklift batteries can offer you the quality of a new product at an affordable price.

They Are Environmentally Friendly

Warehouse operators should be aware of the environmental impact of their work. To make your warehouse better for the environment, use reconditioned batteries instead of new ones.

Doing so will give new life to batteries that would otherwise end up in a landfill. Since forklift batteries have plenty of harsh chemicals in them, they have a much more significant impact on the environment than other types of waste. Environmentally-friendly business practices are also a fantastic marketing opportunity.

Overall, the advantages of reconditioned forklift batteries are too great to ignore. Now that you know why some businesses prefer them, go ahead and purchase some today to start reaping the benefits.

In an ideal world, you would never have to recharge a forklift battery. However, charging your forklift battery is essential for working in a real-life warehouse. In this guide, you will learn about safety practices and procedures for forklift battery charging.

Know the Four Components of a Lead-Acid Battery

According to the Occupational Safety and Health Administration (OSHA), there are four main characteristics of a lead-acid battery that could lead to safety risks. The first is the battery’s weight. These batteries are extremely heavy, and if you drop one of them, you might hurt yourself.

The next is caustic fluids, the electrolytic mixture that powers the battery. This mixture includes sulfuric acid, and if you come into contact with the substance, it will lead to a chemical burn.

Dangerous gases are the third safety risk because batteries will emit hydrogen gas when they’re charging. If the level of hydrogen gas becomes too great, it could lead to a fire or explosion in the charging area.

Finally, there is exposure to electricity since you are dealing with active battery cells. New forklift batteries are less likely to experience problems, but you should understand these components whether your battery is new or used.

Keep the Battery Charging Room in Proper Condition

Keeping your battery charging room properly equipped with all necessary safety gear will ensure that no disasters take place. OSHA requires any battery charging to take place in a designated area that’s separate from other warehouse activities.

This room must have adequate ventilation to prevent the gases and fumes from building up. You can prevent collisions by placing structural barriers around the charging equipment. Water accessibility is another critical component because you will need it for hydrating the batteries and cleaning up electrolyte spills.

Understand Proper Equipment Handling and Training Procedures

Training is the most effective way to maintain safety while charging a forklift battery. As long as all workers are knowledgeable about what to do in any battery handling situation, there shouldn’t be too many problems. In addition, wearing personal protective equipment, such as goggles, rubber gloves, and aprons, will protect you from chemical exposure.

Overall, charging a forklift battery is a safe process if you know what you’re doing. Now that you know about the safety practices and procedures for forklift battery charging, you will be able to charge your forklift battery with ease.

Maintaining your forklift battery is an essential practice if you want to lower your business expenses and improve productivity. However, if you aren’t sure where to begin, you should know that the process for maintaining a forklift’s battery only requires three primary steps. With this in mind, here is a quick guide to maintaining your forklift battery.

Perform Equalization Charges on Your Battery

The more you use a battery, the more a battery cell loses its capacity to hold an electric charge. Your battery won’t operate as efficiently if one of the cells can’t hold a full charge, which is why you will give your battery equalization charges to prolong its working life.

Equalization charges ensure that all the cells in a battery have the ability to hold a full charge. For example, since a normal recharge cycle will be about eight hours for an average forklift battery, you can charge your battery for an additional three or more hours at a lower stream of power to make sure that all the cells have an even charge.

Water Your Forklift Battery

Depending on your machine’s forklift battery, you may need to water it so that the electrolyte mixture isn’t too acidic. When it’s too acidic, the mixture will corrode the connection points on your battery, causing lasting damage.

To make sure that you water your battery the correct amount, keep the water level a half-inch below where the battery cap opening is located. Also, only pour deionized or distilled water, so there aren’t any impurities in the water you pour onto your battery.

Wash Out the Battery Case

Residue from the battery acid will build up on your battery, which is why cleaning off the battery case is a critical component of maintaining your forklift battery. When the battery acid mixes with the lead posts and the steel enclosure, it creates a conductive circuit that emits a small discharge.

This will cause your battery to go through its charge cycles more frequently, which wears it out more quickly. Also, the battery acid corrodes the terminals, and this damage could lead to electrical problems with the forklift itself.

For this reason, you will want to spot clean the tops of your battery cells with an acid-neutralizing de-greaser once per month and the rest of the battery once every three to six months, depending on how often you use it. Otherwise, you will need to start looking for electric forklift batteries for sale to replace your damaged item.

Overall, if you want to protect your forklift battery from damage, you must maintain it properly. Be sure to look back at this quick guide to maintaining your forklift battery if you need any pointers on how to take care of your battery.

Forklifts are an integral tool for any business operating out of a warehouse. Because battery-powered forklifts have advantages over gas-powered ones, many warehouse operations favor using electric vehicles over ones powered by an internal combustion engine.

However, this also means that proper forklift battery storage is critical for the business’s success. Here is your guide on how to properly store a forklift battery.

Fully Charge Your Batteries Before Storing Them

If you plan on storing your forklift batteries for an extended period, fully charge them before putting them away. Doing so will prevent the onset of sulphation, which occurs when batteries have low levels of electrolytes, causing air exposure and sulfate buildup.

Sulphation can adversely affect your battery’s shelf life and performance capability, so charging your batteries before storage could offer you financial benefits and peace of mind. If you need to replace your battery, be sure to lookout for forklift battery sales online.

Place Them in a Dry Location That’s Free of Frost

Keeping your batteries away from frost and moisture is crucial when storing them properly.

As with exposure to air, moisture and frost can corrode the battery. Also, avoid storing your battery in a hot, humid environment due to the moisture in the air.

Disconnect Your Batteries When They Aren’t in Use

Batteries connected to your forklifts will discharge even if the equipment isn’t on. If the discharge continues, your battery could be under a parasitic load and completely discharge over time. To prevent this from happening, disconnect your batteries if you plan to keep them mounted onto the forklifts.

Give Your Batteries a Refresh Charge Once per Month

When your batteries are in storage, you will want to give them a refresh charge once per month to ensure they are fully charged the next time you need to use them. Batteries that sit for too long may die out if they don’t get charged often enough. Store your batteries in charger racks so you can program the racks to give your batteries refresh charges automatically.

Overall, learning how to properly store a forklift battery will ensure that you always have functional equipment on the job. Now that you know a few tips, you can keep your forklift in working order and continue driving with ease.

Although forklift batteries are rechargeable, they will lose their charge at some point during their lifespan and become unusable. When this occurs, you should consider recycling your forklift battery so that it doesn’t harm the environment, which would happen if you chose to throw it away in a landfill.

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