Battery Service and Maintenance

Liftow Forklift Battery Service Division

The Battery Department focuses on helping manage all makes and models of batteries and chargers by providing planned maintenance, service and repairs.

Our goal is to help increase the life of equipment, help reduce unexpected breakdowns, increase safety and help keep our customers new equipment under warranty by following guidelines set by some of the industry’s leading battery manufacturers.

Our technical field staff are professionally trained both in house as well as alongside industry leading manufacturers in Canada and the USA to provide top quality service.


Battery Planned Maintenance

Average life expectancy of a battery is 5 years. Battery life expectancy is determined by usage, duty cycle, maintenance, recharging, watering, etc. Every application is different and to help increase your batteries life expectancy a proper planned maintenance is one of the key factors. We have identified and outlined the major areas of concern for a battery along with some suggestions to help increase productivity of your battery.

overcharging-iconOvercharging… Batteries should not be discharged below the 80% discharged level, except in emergency situations. Continually discharging to 100% discharge level will reduce battery life. Low voltage and high amperage also effects truck components (contact, brushes and motors).

corrosion-iconCorrosion… Corrosion is an indicator of improper watering of batteries. If electrolyte is forced out of the cell it will corrode and weaken the steel tray, as well as causing other external component deterioration. When water is added, the electrolyte becomes diluted and thus loss of capacity. Methods to correct this problem include employing proper watering procedures (filling after charge, not before) and utilize an automatic cell filler or watering system.

cut-cable-iconCut Cables… Cut cables are hazardous because of the possibility of electrical arcing. The burning action of the shorted cables can cause great personal injury. Hydrogen gas is a by-product during the charge cycle and is extremely explosive. Preventative measures include installation of plastic cable wrap. New cables should be replaced by qualified personnel because molten lead and flames are used.

connectors-iconBroken or damaged connectors… Cracked or broken connectors allow the contact tips to be exposed. This can lead to electrical shorting and possible battery explosion and should be repaired or replaced as soon as possible.

Sulfation-iconSulfation… Sulfation is a condition in batteries where sulfuring acid crystallizes on plates and causes a resistance, thus preventing full charge back. If allowed to continue the battery will not accept a charge. Monitoring charging procedure and utilizing the equalize can help prevent sulfation.

battery-damage-iconTray Damage… Corroded or damaged trays can drastically weaken the strength of the steel. Personnel injury and expensive repairs may occur. This can also lead to lift truck compartment and component problems.

Inconsistent Voltages and Specific Gravities… When we see voltages and specific gravities (acid concentration) vary we can expect problems in the near future. Further testing may be required.

dry-cells-iconDry Cells… If electrolyte levels are low enough a portion of the plates will be exposed to air. This allows for sulfation and reduced capacity. Water should be approximately ¾ of an inch higher than the splash guard. Though if cells were exposed to air there may be damage to the cell and testing should be considered. (Only fill water after charge, not before).

Battery Programmed Maintenance Service covers:

  • Battery/Charger Compatibility
  • Cable position
  • Clean and neutralize
  • Check specific gravity and electrolyte level in each cell
  • Reading at ambient temperature Check voltage in each cell Check voltage leak in truck NEG__VOLTS POS__VOLTS
  • Inspect battery positive terminal
  • Inspect for raised positive battery links
  • Inspect battery negative
  • Check battery shrouds
  • Inspect cables for splits and wearing
  • Inspect sealing compound
  • Partial reseal / complete reseal
  • Inspect water indicator
  • Inspect watering system (if equipped)
  • Inspect battery stops and battery locks and latches
  • Advise of battery tray condition (if battery was removed)
  • Inspect battery connector also truck and charger


battery-disposal-greenBattery Disposal
Liftow offers free removal of old and unwanted batteries. The batteries are properly disposed of and the lead, plastic, acid are recycled and reused in the production of brand new products.
Click here to schedule a disposal request.


Battery Charger Service

Liftow Forklift Battery Service Division

Battery Charger Service includes:

  • Name plate identification and verification
  • Check A/C input / DC Output
  • Check ammeter / proper calibration
  • Check and adjust high-low rate control
  • Inspect Rectifier / Transformer
  • Visual Inspection of all connections
  • Clean and lubricate moving parts
  • Clean charger Inspect access door latches and hinge

Battery Cleaning is performed for more than just the visual appearance of the battery. We Neutralize the acid buildup which will reduce the amount of acid that traps in between cells. Acid buildup will corrode the battery cell walls, connectors, cables and may also cause damage to the lift truck’s battery compartment. This can lead to dead cells, shorted out batteries or lift truck component issues.

before and after cleaning battery


  1. What is a forklift battery? A forklift battery is an electro-chemical device that stores D/C power for use in a forklift. It also acts as part of the forklift counterbalance.
  2. How often should I water my battery? Check and adjust water to the proper levels only after the battery has received a full charge.
  3. Why is the light on my battery flashing? This indicates water levels in the battery. Water needs to be checked and adjusted if necessary.
  4. How often should my battery be cleaned? Typically, every 90 days or 60 days in extreme conditions.
  5. When should I charge my battery? FAST CHARGE: whenever the truck is not in use. CONVENTIONAL: Daily for normal use. 2-3 times weekly for light applications
  6. What is a battery monitoring device? This is used to record the battery/charger activities during usage. Information includes such items as i) The daily State of Charge. ii) Weekly EQ Cycles iii) Daily connections iv) Daily Usage (EBU). V) Operating Temperatures.
  7. Why is my battery failing? Here are some of the more common reasons industrial forklift batteries can fail.

Glossary of terms

Battery lifespan will vary depending on use and the conditions which it is used in.

Battery Capacity
When a battery is under capacity, or undersized, for the forklift truck/workload this will cause the forklift truck to underperform its duties.

One or more failed cells will cause low voltage, in turn this will impair the forklift truck operation.

Charger Capacity
If a battery charger is under capacity for the battery, it is not capable of putting enough charge back in to the battery during a regular charging cycle.

Faulty connector(s) can cause poor connections between the battery charger and/or forklift truck.

Industrial Batteries require proper, regular interval maintenance to be done to avoid the accumulation of acid corrosion on/near the battery terminals along the top of the battery.

Faulty Charger
When a battery charger is not putting out enough amperage to charge the battery, it will not allow the battery then to properly charge to capacity.

Incomplete Charging Procedures and Equalize Charging
Most newer style Industrial Battery Chargers include an Equalize setting which allows all of the battery cells to fully recharge. This process typically be done approximately every 10 cycles.

Low Water Levels
Proper Industrial Battery watering is essential for the optimum lifespan of your battery. Too little water in a battery can cause damage to the internal pates that is irreversible.

Over Watering
Industrial Batteries require a sulfuric acid and water mixture in order to operate. Over watering creates a diluted acid mixture which inhibits the proper full function of the battery and requires an acid balance to correct this.

Work Limit
Over working the battery, or excessive usage, will have an impact on the batteries lifespan and overall health.