5 Signs It’s Time to Replace Your Forklift Battery

Shorter runtimes, frequent charging and overheating mean your forklift battery is near the end of its life.

Replacing it on time prevents costly downtime, protects equipment and keeps your warehouse running efficiently. Here’s how to spot the warning signs and how MHS Lift’s parts and service team can help extend fleet life.

Why does forklift battery health matter for your operation?

A weak or aging forklift battery can quietly erode productivity. Operators may notice slower lift speeds, shorter shifts between charges, or overheating – all signs that efficiency and safety are being compromised. Over time, forcing an old battery to perform can damage the truck’s electrical system and drive up maintenance costs.

At MHS Lift, we help customers prevent downtime with proactive parts replacement and 24/7 service.

1. Are your forklifts running out of power faster than they used to?

If your electric lift truck no longer lasts a full shift, even after a full charge, the battery capacity has likely diminished. Most industrial batteries perform reliably for 1,500-2,000 charge cycles – after that, cells lose the ability to hold power effectively.

Pro tip:

Track runtime data through our fleet telematics system on My Fleet 365 to see patterns in energy performance and detect weak batteries early.

2. Are you charging more often than normal?

Frequent charging is a red flag. Overcharging or “opportunity charging” throughout the day stresses the cells and shortens battery life even more. If operators are plugging in trucks mid-shift to stay productive, it’s time to evaluate battery health or charging infrastructure.

3. Do you notice overheating or corrosion?

Excessive heat or visible corrosion on battery terminals suggests internal resistance or fluid imbalance. Overheating can warp plates and cause acid leaks – both safety and equipment hazards.

Maintenance tip:

MHS Lift’s Preventive Maintenance Program includes scheduled inspections, cleaning and electrolyte checks to prevent corrosion and spot early failure signs.

4. Is your forklift performance inconsistent?

Jerky operation, slow acceleration or dimming lights during lifts often indicate voltage drops caused by a failing battery. Consistent power delivery is critical for operator safety and equipment longevity.

MHS Lift technicians can run a full battery load test and recommend replacement or reconditioning options to restore reliability.

Are your maintenance costs climbing?

If your team spends more time and money on electrical repairs or unexpected downtime, an aging battery could be the hidden cause. Replacing it before total failure protects motors, controllers and chargers from strain.

Frequently Asked Questions (FAQ)

Q1: How long should a forklift battery last?
A1: Typically 5-7 years, depending on maintenance, charge cycles and operating environment.

Q2: Can I recondition a weak battery instead of replacing it?
A2: Sometimes – if plate damage isn’t severe, MHS Lift can recondition the unit to restore some capacity.

Q3: What happens if I delay battery replacement?
A3: Underperforming batteries strain your forklift’s electrical system, increasing the risk of failure and higher repair costs.

Q4: How can I make my batteries last longer?
A4: Follow correct watering schedules, avoid overcharging and schedule quarterly inspections.

Q5: Does MHS Lift service all forklift brands?
A5: Yes. Our certified technicians service all makes and models and maintain regional parts inventories.

Don’t wait for downtime to hit. Schedule a battery health inspection or ask about our Preventive Maintenance Programs today. Request service at MHSLift.com/parts-service.