What are the Daily Maintenance Practices for Forklift Batteries?

Proper maintenance of batteries is crucial to ensure their optimal performance, longevity, and safety. This guide provides valuable tips for the routine care of forklift batteries, including monitoring fluid levels, cleaning the battery surface, performing balanced charging, safe storage practices, handling electrolytes, and managing end-of-life batteries. Follow these guidelines to maximize the lifespan and efficiency of your batteries.

Maintenance Guide:

  1. Fluid Level: Perform a comprehensive fluid level check every week (add distilled water or deionized water every three days in high-temperature environments). Low electrolyte levels can damage battery plates and separators, reducing battery life. To check the fluid level, open the filling cap. If the level is below the bottom platform inside the filling cap, it indicates that the fluid level is too low and needs to be replenished. If the level is parallel or slightly above the top platform inside the filling cap, it is at an appropriate position.
  2. Terminals, Cables, and Covers: Regularly inspect the battery terminals for corrosion caused by oxidation at the connection points and cables. Also, check if the covers are deformed or experiencing any heating issues.
  3. Exterior: A dirty battery surface can cause electrical leakage. Keep the battery surface clean and dry.
  4. Watering: Add distilled water or deionized water according to the recommended fluid level. Avoid adding excessive amounts of distilled water to prolong the watering interval, as it can decrease the specific gravity and cause electrolyte overflow, leading to corrosion of the battery casing and cables, thereby affecting battery lifespan or causing leakage.
  5. Charging: Charging the battery generates gas, so ensure proper ventilation and keep away from open flames during the charging process. The oxygen and acidic gases produced during charging can have an impact on the surrounding environment. When disconnecting the charging plug during the charging period, make sure to turn off the charger before unplugging. After charging, there will be a significant amount of hydrogen gas around the battery, so no open flames are allowed. Lift the cover on the battery to charge it.
  6. Maintenance of Terminals, Cables (connecting plates), and Covers: This should be done by professionally trained personnel designated by the manufacturer.
  7. Cleaning: Keep the battery surface clean. Dirt on the surface can cause short circuits and corrosion of terminals and connecting bars. When cleaning, use a damp cloth to avoid static electricity. If there are no liquid discharge holes at the bottom of the battery box, avoid rinsing with water to prevent excessive water accumulation, which can corrode the battery casing. If there are liquid discharge holes at the bottom, you can rinse it slowly with water in an open area.

Balanced Charging:

Perform a balanced charging once a month for the battery pack to maintain capacity and extend battery life. Balanced charging involves low current charging over an extended period.

Balanced charging method: First, perform a normal charging process. Once the charging is complete, activate the balanced charging mode and continue charging for 24-36 hours. During balanced charging, measure and record the voltage, density, and temperature of each individual battery. Adjust the density and fluid level of the electrolyte to comply with the specifications stated in the user manual before completing the charging process.


  1. Storage Location: Store the batteries in a well-ventilated and cool place to prevent short circuits. Rainwater can cause short circuits, leading to fires and the release of hydrogen gas. Therefore, batteries must be stored in a ventilated and shaded area.
  2. Disposal of Used Batteries: Used batteries still retain electrical energy and should be stored following the same methods as in-use batteries.
Maintenance Practices for Forklift Batteries
What are the Daily Maintenance Practices for Forklift Batteries? 3

Handling of Electrolyte:

  1. Specific Gravity Check: Use a suction-type hydrometer to check the specific gravity of the electrolyte. Take precautions to avoid splashing electrolyte and wear appropriate protective gear.
  2. Operations other than checking: Consult with a professional, especially when replenishing electrolyte.
  3. Electrolyte Leakage: In the event of electrolyte leakage caused by battery tilting or damage, take immediate emergency measures.

End-of-Life Battery Operation:

  1. Operation of End-of-Life Batteries: When batteries approach the end of their life, the electrolyte in individual cells decreases rapidly. In such cases, replenish distilled water daily.
  2. Disposal of Used Batteries: Discharge the electrolyte from used batteries and dismantle them. Consult with the battery manufacturer to determine if they provide recycling services.

Other Precautions:

  1. Battery packs have high voltage and pose an electric shock hazard. Wear insulated gloves when performing maintenance.
  2. The battery temperature should not exceed 60°C during use.
  3. Do not place any repair tools or other metal objects on the battery surface.
  4. When the battery capacity drops below 80% of its initial capacity, replace it based on regular inspections.
  5. If electrolyte comes into contact with the skin or eyes, flush with plenty of water and seek immediate medical attention.
  6. If electrolyte spills onto clothing, remove the clothes immediately and rinse with water. Then wash with a weak alkaline soap solution.
  7. In the case of electrolyte leakage, neutralize it with lime, strong soda ash, or baking soda, and flush with plenty of water.

By implementing these battery maintenance practices, you can extend the lifespan of your batteries, enhance their performance, and ensure safe usage. Take proactive steps today to maintain your batteries and enjoy reliable power supply in your everyday life.


Taking care of your batteries through regular maintenance is essential for their longevity and safety. From monitoring fluid levels and cleaning the battery surface to performing balanced charging and proper electrolyte handling, each step plays a vital role in preserving battery health. Remember to follow recommended guidelines and consult professionals for any repairs or disposal of end-of-life batteries. By adopting these practices, you can optimize the performance of your batteries and ensure their reliability in powering your devices.


  • Shanghai Zhongsheng Industrial Co., Ltd
  • Website: Zospowerpower.com
  • Phone: +86-15026665707
  • Email: [email protected]

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