A few days ago, we talked to you about the advantages of lithium battery forklifts compared to diesel forklifts, or even forklifts with lead-acid batteries. As it is increasingly common to find in the market an offer of handling machinery that incorporates lithium batteries, (for example, in the Manain fleet you can test them), in this post, we want to provide maintenance and usage tips.

First, you might wonder why the use of lithium batteries is becoming more frequent in forklifts, pallet trucks, reach trucks, or stackers. Simply because it has been shown that the lithium battery, compared to the lead-acid battery, offers a higher energy concentration in a smaller space. For the manufacturer, this means the ability to design more robust forklifts, with greater durability and up to 30% more efficiency. And for the operator, this means having forklifts that can be charged as needed, with a long battery life and better investment amortization.

According to manufacturers, forklifts with lithium batteries require less maintenance. However, this doesn’t mean we should forget to care for our forklift during use and especially during storage. Because prevention is always our best solution to enjoy an electric forklift for many years.

When should I charge the lithium battery of my forklift?

Whenever you want. One of the advantages of lithium batteries over lead-acid batteries is the opportunity charging. What does this mean? It means you don’t have to wait for the battery to be minimally discharged or fully charged. Charge it as needed. For example, take advantage of shift changes to charge it a bit. The ideal is to keep it between 20% and 60%.

But… if I charge the lithium battery without it being fully discharged, could it damage my forklift?

Partial or occasional charges do not harm the lithium battery’s capacity at all. A lithium battery can last up to 3,000 charge cycles (depending on the battery size). Because its lifespan is three times longer compared to lead-acid batteries.

How do I charge my forklift’s lithium battery?

First, always use the charger recommended by the manufacturer. If for some reason you’ve lost it and need to use another one, make sure it has the same voltage.

Remember, it is not necessary to wait for it to be fully discharged. Plug it in, and when the charger’s green LED lights up, it means it’s fully charged. Unplug it once charged. Keep in mind that because lithium batteries have a high energy density, they are up to 5 times faster to charge compared to lead-acid batteries. So, it’s not necessary to leave the forklift plugged in overnight.

Are there any precautions to consider during charging?

Always check that there is no activity nearby that could generate fire residue, nor any inflammable material close by. Avoid charging it at temperatures above 48ºC. Keep the area ventilated.

Keep in mind that cold reduces the battery’s capacity and delays charging. On the other hand, heat can cause overcharging.

Finally, we provide some recommendations on where to store your forklift, pallet truck, stacker, or reach truck with a lithium battery when you are not working.

• Avoid storing the electric forklift with a lithium battery in a place exposed to high or low temperatures. Lithium is very sensitive. Long exposure to temperatures above +60ºC or below 0ºC can damage the lithium battery, affecting its lifespan by up to 25%.
• Ensure the battery is also protected from moisture. Avoid direct exposure to water or other materials that could damage it.
• If you need to store it for an extended period, it is better not to leave it fully charged, as it will lose energy much faster. It is recommended to leave it with an intermediate charge of 40%.

*Other cited sources: https://blog.toyota-forklifts.es/bateria-carretilla-elevadora-funcionamiento