Forklift Battery

Forklift Battery Type

Lead-Acid Wet Cell Forklift Batteries

Lead-acid wet cell batteries are standard flooded lead-acid batteries. Lead-acid technology was the industry standard for decades. The recently developed valve-regulated lead-acid (VRLA), gel, absorbent glass mat (AGM), and thin plate pure lead (TPPL) varieties overcome some of the inefficiencies and safety issues of this chemistry, but only demonstrate average performance. Commonly used in passenger and commercial vehicles, they are very heavy and only allow a maximum of 60% of their nominal capacity to be used. However, new lead-acid batteries are inexpensive to purchase initially, which is why many companies continue to use them in their forklifts.

All versions of lead-acid batteries have a cycle life of 4-5 times shorter than newer available options. They have to stay on charge for many hours and can’t support single-battery operation, especially in multiple-shift and other demanding applications. Because these industrial batteries contain lead and sulfuric acid, they pose a serious environmental hazard during regular maintenance: clean water has to be added to individual cells to equalize their electrolyte levels, which can lead to possible acid spills and the emission of fumes. With increasing maintenance and labor costs, they are a poor choice for forklifts compared to newer options that have become less expensive over the past decade.

Lithium-Ion Forklift Batteries

By comparison, lithium-ion batteries provide a lot of advantages for material handling operations and have come down significantly in price over the past few years. These batteries, which include LFP, NMC, and NCA options, have a higher energy density and can be charged at any time without damaging the battery or shortening its cycle life. They perform much better in cool or even extreme cold and hot temperatures, unlike lead-acid wet cell batteries, which lose capacity and charge in cold conditions.

Lithium batteries increase your forklifts’ utilization rate, increase uptime and provide maximum availability with shorter charging times. They put lower demands on your existing infrastructure with lower electricity consumption and lighter, simpler chargers. Though lithium-ion batteries are still more expensive than lead-acid batteries up front, they have a much longer lifespan, at least twice the cycle life, while improving efficiency and safety in all industrial applications.

What to Know About the Different Forklift Battery Voltages

Volts and Battery Cells
Forklift batteries feature cells arranged in a series. Each cell of a lead-acid battery has a nominal voltage of 2 volts (2V). If your lead-acid forklift battery has 24 cells, it has a voltage of 48V.

The amount of voltage you need depends on the type of forklift the battery must power. In general, the larger the machine and the more strenuous the job, the more volts you’ll need. Consider the following battery voltages and the lifts they can power:
●24V batteries—Small lifts, such as walkie stackers
●36V batteries—Mid-size lifts, such as narrow-aisle forklifts
●48V batteries—Larger machines, like counterbalanced forklifts
●80V batteries—Forklifts from 2.5 tons to 7.0 tons

Volts and Amps
When thinking about different forklift battery voltages in terms of power, it’s important to consider amperes, too. A volt is a measurement of the electrical potential between two points, or the pressure at which electricity flows in a system. In contrast, an ampere is a measurement of electric current, or the number of electrons moving through a circuit.

To avoid damaging your battery, maintain at least 20 percent of the full ampere-hour (AH) capacity of your battery. Discharging below 80 percent will lower the voltage per cell and cause overheating and other damage.

Volts and Battery Size
The higher the voltage and capacity, the heavier the battery. Because of their materials and chemical processes, lead-acid batteries tend to weigh more than lithium-ion batteries of the same voltage.

Because cells can be arranged in different ways, batteries of the same voltage may have different dimensions. For example, a 24V battery can have either two rows of six cells each, or three rows of four cells each. Forklift weight and size impact your storage considerations and equipment requirements for charging and servicing the battery.

If you’re in need of a new or refurbished battery, shop with GEB Forklift Batteries.

What is the difference between forklift batteries and a car battery?

Capacity – Forklift batteries have much more powerful understandable. Forklifts have a 100Ah capacity, approximately double a cars.

Voltage – Forklift batteries have a higher voltage due to needing more power to run. Typically they are 48V while a car is generally 12V

Size – If you’ve ever seen a forklift battery you’ll realize they are much, much bigger than a car battery.

Care – Generally a car battery needs very little maintenance, while a forklift truck will experience more stress and wear and tear due to the work it receives and therefore needs regular TLC.

Toughness – Forklift batteries are built for exposure to tough working conditions such as knocks, bangs, vibrations and temperatures. Car batteries experience much less abuse.

When To Repair or Replace Your Forklift Battery

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.

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.

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.

Safe Charging

●Keep all metallic items, such as jewelry and tools, away from the charging area to prevent electric shock.
●Keep the battery covers open while charging to facilitate proper heat dispersal.
●Never add acid to a battery, and only add water after a battery charges and cools.
●Always turn the battery charger off and unplug it before detaching or attaching the connector.
●Turn the charger off immediately if you see any leaks or notice that the battery temperature increases — you can continue at a lower charge after the battery cools.

Maintaining Forklift Battery Capacity

Both lithium-ion batteries and their lead acid counterparts should be cared for properly if they are to perform up to their full potential. Their service life will diminish if proper forklift battery maintenance is not carried out as it should be.

In order to maximize service life and overall battery capacity, certain measures should be taken for users of both battery types. However, lead acid batteries require more care and attention compared to lithium-ion.

Lead acid forklift batteries require

●Equalizing (Cell Balancing): Traditional technology like this leads to a frequent state where the acid and water inside become stratified (separated horizontally with the acid more concentrated closer to the bottom). This state forms sulfate crystals towards the bottom of the cells and weakens their ability to hold a charge. Equalizing will break up the sulfate crystals but if the battery has been neglected for too long the crystals will not break.
●Temperature Control: Lead acid batteries must be kept within a certain temperature range, or else they will have a shorter working life. On top of that, they also get very hot while charging, which requires them to be charged and stored in a temperature-controlled space.
●Fluid Level Management: These types of units must be checked to ensure they have enough water about once every 10 or so charging cycles.

Lithium-ion batteries are much less needy when it comes to forklift battery maintenance, as they equalize automatically, function well in much higher temperatures (making temperature mostly a non-issue), and do not require any fluid level management.

How Long Does a Forklift Battery Last?

Lithium-ion batteries usually last for 2,000 to 3,000 charge cycles, while lead-acid batteries for 1,000 to 1,500 cycles.

That sounds like a clear win for lithium-ion batteries, but if you have multiple shifts, with lithium-ion batteries being charged regularly throughout each day, then the life of each battery will be shorter than if you were using lead-acid batteries that are removed and swapped at the start of each shift.

Lithium-ion batteries are lower-maintenance than lead-acid batteries, which can mean they last longer before they reach their end of life. Lead-acid batteries need to be kept topped up with water to protect the lead plates inside them, and they will become damaged if they are allowed to get too hot or too cold.

Risks of Using a Damaged Battery

Using a damaged battery can risk more than losing power to your forklift. Batteries – particularly the common lead-acid type – contain dangerous and corrosive chemicals such as sulfuric acid produced hydrogen gas when charging, which can cause physical injury. Fires can also be a hazard associated with the use of damaged batteries.

When inspecting, repairing, or replacing a damaged battery, it’s important to wear the correct PPE. This generally includes rubber gloves and an apron, goggles or a face shield, and protective footwear. It’s also advisable to be in close proximity to a first aid kit and an eyewash station.

FAQ

Q: What type of batteries does a forklift truck use?

A: Forklift truck batteries are classified into two types: lead-acid and nickel-cadmium. Because of their low cost and high energy density, lead-acid batteries are the most commonly used type of battery for forklifts. Nickel-cadmium batteries, on the other hand, are gaining popularity due to their longer lifespan and ability to handle high power demands.

Q: How long will a forklift truck battery last?

A: The life of a battery is generally expressed as a number of charging cycles. So basically, the length of time your forklift truck battery lasts is dependent on how many times you charge and discharge it. A good rule of thumb to maximize its life is to charge it only when it’s more than 60% discharged but less than 80% discharged. While it’s also dependent on things like the operating conditions and how often it is being used.

Q: Are forklift batteries different from car batteries?

A: Yes. Forklift truck batteries have a higher voltage due to needing more power to run.

Q: What are signs of replacement?

A: When your forklift battery doesn’t hold a charge like it used to, that's a sign you may need to replace it soon. That said, if the battery is only a few years old/has fewer than 1,000 charging cycles, you may be able to repair rather than replace it.
Here are few more signs your forklift battery is going bad:
Corrosion on the battery case
Spilled acid on the exterior
A rotten egg smell
Smoke
Corroded or damaged terminals
Dim or flickering displays
Poor response time

Q: How should I do if the forklift battery malfunctions?

A: Sometimes It’s An Easy Fix: Slow performance and dim displays might be caused by a loose connection. Cables can come loose, wear out, or aren't reconnected properly after charging. Have an experienced operator with proper training inspect the connections and check for signs of corrosion or wear. They should also clean the connection area(s) properly before reattaching any loose cables.
Sometimes You Need a Professional: If your battery emits smoke at any point, power down the forklift or charging equipment immediately. A smoking battery can catch fire or explode.
If the operator finds corroded or damaged terminals, excessive sulfation or acid leakage, have the battery inspected by a professional. Excessive sulfation and acid leakage are typically caused by underwatering (sulfation) and overwatering (acid leakage). In either case, the battery will be covered in a hazardous substance.

Q: What are Lead-Acid Forklift Batteries?

A: Lead-Acid forklift batteries are rechargeable batteries that have a high power-to-weight ratio and are sought after due to their lower cost. They are known as motive batteries, AKA the motor of the vehicle.

Q: What are Lithium-Ion Forklift Batteries?

A: Lithium-Ion forklift batteries are rechargeable lithium and graphite batteries with a very high energy density, low discharge rate and no memory loss.

Q: When to Add Water to a Forklift Battery?

A: The best time to water your batteries is right before a shift, after the batteries have had time to cool down.

Q: How Much Does a Forklift Battery Weigh?

A: A forklift battery weighs between 800 to 4,000 lbs. depending on the type (lithium-ion vs lead-acid) and size (24V, 36V, 48V).

Q: Is It Worth It to Buy Lithium Forklift Batteries?

A: The short answer is: If you are a medium to large-size operation running multiple shifts, lithium-ion forklift batteries could be a very good option for you.

Q: What Is the Biggest Advantage of a Lithium-Ion Forklift Battery?

A: Increased runtime and more productivity. This is because Li-ion batteries don’t lose power like lead-acid and since they can charge quicker (opportunity charge). But lithium-ion batteries are also cost-effective and return the RIO in the long run because of increased efficiency, reduced costs (electricity and labor), and improved productivity.

Q: How Long Does It Take to Charge a Lithium-Ion Forklift Battery?

A: A lithium-ion forklift battery can charge up to 80% in an hour. But Li-ion batteries can also charge throughout the day in 15- or 30-min spurts or fully charge in 1 to 2-hour continuous sessions. Compared to the 8-hour charge time plus an additional 8-hour cooldown time for a lead-acid battery, lithium-ion batteries are more efficient.

Q: Is It Okay to Leave a Lithium-Ion Battery on the Charger?

A: Leaving a lithium-ion battery on a charger is okay. The batteries generally have onboard computer controllers that monitor charging and will shut down once they’re charged. This helps stop overcharging.

Q: Can a Lithium Forklift Battery Be Overcharged?

A: It’s possible for a lithium forklift battery to be overcharged, though it rarely happens. Lithium forklift battery charges to full charge in between 1 to 2 hours. Once plugged in, it won’t overcharge because of the onboard computer controllers that monitor charging and will shut it down once it’s charged.

Q: Can a Lithium Forklift Battery Be Over-Discharged?

A: Most lithium-ion forklift batteries have a depth of discharge ranging from 80% to 100%. Avoid over-discharging a lithium battery because doing so can potentially cause individual cells to discharge at different states, resulting in the battery’s permanent damage.

Q: What Is the Average Lithium Forklift Battery Operating Temperature?

A: Lithium batteries can operate in nearly any environment, with temperatures ranging from -4° F to 130° F. That said, the optimal operating temperature range is between 50° F and 110° F.

Q: Can improper watering turn into a safety hazard in warehouses?

A: Yes! When acid gets trapped in the battery plates, you can’t maintain appropriate fluid levels. Eventually the fluid overflows, and acid spills on the batteries and floor. When employees water batteries improperly, they can get acid on themselves, which could cause dangerous acid burns.

Q: How do I know if my forklift battery is bad?

A: There are several signs that your forklift battery may be bad or need service or refurbishing. Signs that a forklift battery is bad or in need of repair may include:
Decline in performance, power and/or battery life.
Evidence of spilled acid on or near the battery.
Signs of corrosion or damage to the battery terminals.
Battery gives off a rotten egg smell.
High operating temperatures.
Battery starts smoking.
Lights on the display of the forklift go dim or flicker.
Damaged cables, connectors or contact tips.

Q: How are forklift batteries measured?

A: To calculate accurate battery size, be sure to measure from the external edge of the steel tray that holds the forklift battery. For width, measure the tray from the front to the back of the forklift. For length, measure from one lifting tab to the other, across the width of the forklift. For height, measure from the bottom of the tray to the top of the lifting tabs or battery cover if one is present.

Q: Can a forklift battery explode?

A: No, forklift batteries don’t explode. However, lead-acid forklift batteries do release hydrogen during charging, and lighting that hydrogen gas could blow the plastic top off of the battery cell. You may hear a very loud “pop” but NO fiery blast will result. This hydrogen gas ignition and tops potentially blowing off of cells may also result in electrolyte splashing onto anyone nearby, a very real safety hazard. Proper ventilation—based on the number of batteries residing in the charging area—is essential for ensuring a safe, charging environment. TMS can guide you on proper charging protocols for worry-free, forklift battery charging stations.

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