Battery Care Tips for Electric Forklifts and Pallet Trucks
Photo Credit: Hannaman Material Handling
Electric forklifts and pallet trucks are becoming a go-to choice in UK warehouses and distribution centres, thanks to their low emissions, quiet operation, and cost-effectiveness.
But to ensure these machines perform at their peak, taking care of the batteries is crucial.
If you overlook battery maintenance, you might face decreased performance, unplanned downtime, and expensive replacements. So, here are some handy tips for battery care that will help you maximise the efficiency of your electric fleet.
1. Charge Smart – Not Just When It’s Convenient
One of the biggest mistakes people make with batteries is charging them whenever it’s easy, instead of when they really need it.
- Try to avoid partial charging during breaks unless your batteries are specifically designed for that.
- Aim for a full charging cycle once the battery dips to about 20–30%.
Frequent partial charges can really cut down a battery’s lifespan, especially with lead-acid types. If you find yourself using batteries often, you might want to look into lithium-ion options, which handle opportunity charging much better.
2. Top Up Water Levels (For Lead-Acid Batteries)
If you’re working with lead-acid batteries, keeping an eye on the water levels is super important.
- Check the electrolyte levels weekly (or follow the recommendations).
- Only add water after the battery has been fully charged.
- Use distilled water to prevent mineral build-up.
Overfilling or using low-quality water can harm the battery’s internal parts and lower its efficiency.
3. Let Batteries Cool Before Charging
Batteries can get pretty hot during use, and charging them right after can raise their internal temperatures even more, which can lead to quicker wear and tear.
- If you can, let the battery cool down for 15–30 minutes before plugging it in.
Some of the newer batteries come with built-in temperature monitoring systems, but it’s still a good idea to plan your charging during breaks or shift changes.
4. Keep Terminals Clean and Corrosion-Free
Dust, dirt, and corrosion around battery terminals can mess with energy transfer and even cause short-circuits.
- Make it a habit to clean the terminals regularly using a battery cleaning kit or a mix of baking soda and water.
- Check for corrosion and make sure to tighten any loose connections.
A clean battery is a happy battery!
5. Keep an Eye on Battery Health with Telematics
Today’s electric forklifts and pallet trucks can come equipped with telematics systems that track battery usage, charging habits, and overall performance over time.
- Use this information to anticipate when batteries might need maintenance or replacement.
- Identify inefficient charging practices and provide training for operators as needed.
This proactive strategy not only saves money but also helps avoid downtime.
6. Steer Clear of Deep Discharging
Regularly letting batteries drain down to 0% can drastically reduce their lifespan.
- Aim to recharge when the battery hits around 20–30%.
- Avoid deep discharge cycles unless the battery is specifically designed for that purpose.
This is particularly important for lead-acid batteries, which can suffer permanent damage from deep discharges.
7. Store Batteries the Right Way
If your forklift or pallet truck will be sitting idle for a while, proper battery storage is crucial.
- Charge the battery before putting it away.
- Keep it in a dry, cool place, away from direct sunlight.
- Disconnect it from the vehicle to prevent any parasitic drain.
You might also need to charge the battery periodically during storage to keep it in good shape.
Final Thoughts
Caring for your forklift and pallet truck batteries goes beyond just extending their lifespan – it’s about maximising efficiency, cutting costs, and ensuring your operations run smoothly.
At Hannaman Material Handling, we provide comprehensive battery servicing, replacement, and maintenance advice as part of our support services for forklifts and pallet trucks.
Need assistance managing your battery fleet or looking into lithium-ion options? Reach out to our team today for expert guidance and support throughout the UK.
You can also download our handy Battery Care Checklist and Battery Care Do’s and Don’ts here.
