What is a forklift battery?

The automobile industry has revolutionized electric vehicles, and most companies mass produce and sell electric and hybrid vehicles. These vehicles are better for the environment, have cheap operational costs, and do not require much maintenance very often. Forklifts also used to work on engines previously, but now most are shifting towards EV technology.

Like electric cars and trucks, a forklift is also supported by a battery specifically known as a forklift battery, which is much different than normal car batteries.

What is equalizing a forklift battery?

While electric vehicles use lithium-ion batteries, that is not the perfect choice for a forklift. That’s why lead-acid batteries are used in forklifts.  When these batteries operate, there can be a build-up of sulfate in the cells, which can significantly drop the battery's performance.

Equalizing the forklift battery is a process that removes that build-up to restore the battery's performance, and it is done by purposely overcharging the battery.

How to equalize a forklift battery?

Equalizing the forklift battery is not a complex process, but certain requirements and steps must be followed, as discussed below:

1.Get the batteries fully charged with normal charging and disconnect all loads from the battery. Also, remove the hydro caps from the battery.

2.Now connect the charger to the battery and set it to an equalizing voltage according to the battery. For a 12-volt battery, the equalizing voltage will be 15.5 volts.

3.As the battery charges, it will start gassing and bubbling. Meanwhile, its temperature will also increase. You must frequently take measurements from the mid cell and never let the temperature rise above 115 degrees Fahrenheit.

4.Keep taking gravity measures hourly, and when the gravity does not rise above a specific limit, the battery equalizing is complete.

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5.Continue taking gravity measurements until gravity reaches 1.265. Let the battery charge for another 3 hours, and connect all the loads after it cools down.

This process can take several hours, depending on the sulfate build-up on your battery cells. It is recommended to check the electrolyte levels after the process, and equalizing your forklift battery is recommended after every 10-15 charging cycles.

What voltage is a forklift battery?

Whether your car has a small or big battery, the voltage will always be 12 volts. However, that is not the case with a forklift battery. It is because the forklift battery ranges between 48 and 120 volts depending on the size of the forklift.

Why do different forklift sizes use different batteries?

Every forklift is designed to lift a specific weight load for a specific time. The smaller ones frequently lift small weights, while the bigger ones are used for lifting very large weights. So, specific voltage readings, current drawing capacity, and amp-hour capacity are required from the battery. That is the reason why different forklifts use different battery sizes.

Here is the breakdown of different battery voltages forklifts use depending on the weight:

1.48 volts for 1.6-2.5t

2.80 volts for 2.5-7t

3.96 volts for heavy-duty forklifts

4.120 volts for very large forklifts and trucks

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Benefits of using the right voltage forklift battery

Since there are different forklift battery options available, one may think about installing a bigger one in the forklift to get more working time or using a smaller battery for a cheaper option. However, none of these ideas are practical, and here is why:

Cost-effective

Using the right battery for the right forklift size makes it budget-friendly. It is because that battery will get the desired amount of charging, and for smaller forklifts, that will be more than enough. So, it will be cost-saving for you both ways. It also provides efficient performance.

Long-lasting

The right battery lasts long and makes the equipment last longas as well. The forklift is designed according to the battery voltage, so when you use the right battery, electronics and the battery last long.

What is the life expectancy of a forklift battery?

No matter how little your electric forklift is used, the battery lasts only for a specific time. These batteries are designed to last around 15,00 charge cycles. With that said, if your forklift is used only for a single 8-hour shift, it will last for around 5 years. Similarly, if the forklift is used for 2 shifts daily, the battery life will decrease to 2.5 years. These expected lifespan ratings are for the battery, considering it is correctly maintained.

What are the maintenance requirements of a forklift battery?

It is known that the electric forklift won't require much maintenance like a normal combustion engine forklift would. However, there are some battery maintenance requirements which are as follows:

Battery Care

The first maintenance requirement is battery care. Your battery needs to always have electrolytes in it. The electrolyte helps in the charge and discharge process. Additionally, correct charging and discharging practices must be followed.

Equalization

These batteries get sulfate build-up after some time of usage. So, it is recommended that you equalize the battery after a maximum of 15 charge cycles. That will keep the battery running very well for a good time.

Temperature Monitoring

High temperature is among the biggest enemies of these batteries. So, when the battery is being charged, you must keep it at 15 degrees Celsius and 25 while in use. Apart from that, there are no maintenance requirements.

How can you make your forklift batteries last longer?

Here are some tips you can follow to make your forklift batteries last longer:

Once you start charging, charge completely.

Don’t let it completely discharge.

Don’t let the discharged battery sit for more than a few hours

Never over-discharge the battery

By following all these tips, you can preserve the expected life of your batteries for much longer.

Conclusion

Using engines in forklifts brought multiple problems, including restrictions on indoor usage, fuel consumption, environmental harm, and high operational costs. So, this switch of forklifts towards EV technology resolves many of those problems. 

However, for the best results knowing everything about a forklift battery is essential since there is a lot that can go wrong if you make a minor mistake. We hope this article has covered everything you want about forklift batteries.