How to Identify Fork Truck Battery Damage and Replacement

In modern logistics and manufacturing industries, fork truck battery serves as the “energy heart” that ensures continuous equipment operation. Whether using traditional lead-acid batteries or newer forklift lithium-ion batteries, their performance directly determines forklift efficiency and operational costs.
So, how can you tell if a battery is damaged? When should it be replaced? And which type of battery is worth the investment? This article will address these questions one by one.

1. How to Determine if a Fork Truck Battery Is Damaged?

As usage time increases, forklift battery performance gradually declines. Here are five key signs indicating potential battery failure:

Excessive Sulfation in Forklift Batteries

When a battery remains undercharged for extended periods, irreversible lead sulfate crystals form on the electrode plates, leading to reduced capacity and unstable voltage. This issue is common in lead-acid batteries and is difficult to repair once severe sulfation occurs.

Abnormally Rapid Discharge After Charging

If a fully charged battery supports significantly shorter operation times (e.g., only half the original runtime), it indicates increased internal resistance and diminished chemical activity. Severe capacity loss warrants replacement.

Reduced Forklift Performance / Dimmed Display Screen

Unstable battery voltage directly affects forklift power performance. Symptoms like slower acceleration, weak climbing power, and a dimmed display screen are all signs of battery degradation.

Acid Leakage on Battery Exterior

If the battery case shows signs of acid leakage, corrosion, or bulging, it indicates excessive internal pressure or seal failure. This not only shortens lifespan but also poses safety risks.

Corroded or Damaged Terminals

After long-term use, battery terminals may oxidize, loosen, or burn, causing poor contact and reduced power output. Terminals should be cleaned or replaced promptly to avoid damaging the entire battery pack.

2. Expected Lifespan of Forklift Batteries

The lifespan of a battery for forklift varies by type, application, and maintenance, generally ranging from 3 to 15 years.

Key factors affecting battery lifespan include:

• Charging Method: Overcharging or deep discharging accelerates degradation.

• Usage Environment: High temperatures accelerate aging, while low temperatures affect discharge.

• Maintenance Level: Lead-acid batteries require regular watering, cleaning, and equalization charging.

• Workload Intensity: High-load, prolonged operation shortens battery life.

3. Optimal Battery Choice for Forklifts

In modern logistics systems, more companies are transitioning from lead-acid batteries to forklift lithium-ion batteries. With their longer lifespan, higher efficiency, and maintenance-free features, lithium batteries have become the mainstream power choice for forklifts.

For example, Baufar Lithium Batteries use premium cells from brands like EVE and CATL, combined with a self-developed smart BMS for efficient energy management and temperature control. These batteries are widely used in electric forklifts, stackers, and AGVs, offering over 3500 cycles to meet multi-shift, 24/7 operational demands.

4. Conclusion

Whether using traditional lead-acid batteries or modern lithium-ion batteries, proper usage and maintenance are key to extending lifespan. For companies pursuing high efficiency and long-term returns, lithium forklift batteries have become an irreversible trend.