When To Repair vs. Replace Your Forklift Battery

Forklift batteries keep your business moving. So, when your forklift battery becomes unreliable, you must take care of it quickly. Consider the following factors to decide when to repair versus replace your forklift battery.

1. Charging Cycles and Battery Age

In general, standard forklift batteries can last for up to 1,500 charging cycles. After this point, the battery might stop fully charging. If you charge once a day, this equals about five years of use. Once your battery reaches this point, replace it with a new or refurbished battery.

To get the most out of your battery’s lifespan, charge it when it reaches between 20 and 30 percent discharge. Waiting for the battery to drop to a lower level can create performance issues. Let the battery charge completely, as an incomplete charge will still count against your battery’s charging cycle limits.

2. Damaged Components

Another factor when deciding if you should repair or replace your forklift battery is if it has damaged components. Daily inspections can alert operators and facility managers to possible issues. As part of routine maintenance, regular inspections done by trained forklift battery technicians can discover and diagnose problems that owners might otherwise miss.

Watering the cells adequately, washing the battery case, and equalization charges can help prevent damage. Once parts become damaged, a technician can assess the extent of the problem and either make repairs or recommend a replacement.

3. Reduced Performance

Reduced performance can indicate improper care, loose connectors, damage, or the end of the battery’s lifespan. Depending on the cause, you might be able to make changes to your routine or repairs to the battery. For deeper issues, you might need to replace the battery instead.

Tighten loose cables and connectors. If you can’t tighten these parts, or if they’re visibly worn, replace them.

Avoid overheating the battery by ventilating it and giving it time to cool down completely between shifts. Avoid over- and under-charging the battery for the best performance. And water your battery to maintain electrolyte levels and prevent damage.

When it’s time for a replacement, shop for new or refurbished forklift batteries from Green Power Forklift Batteries. At a minimum of 85 percent of the rated capacity of a brand-new battery, refurbished batteries are a reliable and economical way to power your forklifts. Contact us today to learn more.