Female factory worker sitting on forklift and writing on a clipboard.

Forklift maintenance is more than best practice — it’s essential to keeping your investment in material handling machinery in top working condition, providing a safe workplace for your employees and meeting your OHS obligations.

Along with reactive maintenance (repairs) and preventative scheduled forklift maintenance, which we’ll discuss here, routine checks keep your forklifts operating safely and optimally. They also minimise operational costs and workplace risks by identifying potential issues early on. Here we look at scheduled forklift maintenance and how to implement a proactive checklist that protects your investment in quality material handling machinery.

Creating a Forklift Maintenance Checklist

A systematic check of the forklift’s operational systems on a scheduled basis (monthly and quarterly) isn’t only essential but easy. Ideally, use a spreadsheet so that you can keep digital forklift servicing and maintenance records, but a paper form is fine. What’s most important here is covering everything on the checklist. This typically includes:

Safety systems

The safety system on a forklift includes the brakes, steering and tyres. You should check these as part of a routine daily check but give them a more comprehensive check during scheduled maintenance inspections.

  • Check the tyre pressure and look for any signs of damage or wear and tear.
  • Check the brakes for correct stopping response as well as the brake fluid, topping up or replacing if necessary.
  • Check the steering and how the forklift handles. Also check steering fluids and top up or replace if required.

Hydraulics and lifting system

The hydraulics and lifting system on a forklift are among its most important features. These systems must be thoroughly checked and hydraulic fluids kept free of contaminants and topped up to correct levels. Quality hydraulic fluids help to protect these critical features.


If the engine doesn’t function properly your forklift won’t operate optimally, which puts your business at risk of costly downtime. Forklift engine maintenance should always be carried out by a qualified mechanic and includes:

  • Checking and replacing the engine oil
  • Cleaning the air filter and replacing when required
  • Checking the spark plug, rotor, drive belt tension and distributor cap
  • Lubricating the mast and chassis components.


Forklift batteries should be given a quick inspection whenever charging and require extra attention during a scheduled service to ensure they’re working correctly and safely. The proper water level of lithium-ion forklift batteries must be maintained to provide safe and effective charging. This ensures there’s no risk of overflow and the battery doesn’t overheat.


Don’t overlook the importance of ensuring all gauges are working correctly. When gauges don’t register properly there’s a risk that the operator isn’t alerted to a potential issue.

Water, oil and lubricants

Water and oil must be kept at the correct levels at all times and topped up or replaced as part of a monthly or quarterly maintenance service.

With locations in NSW, QLD, VIC and WA, and the capacity to assist businesses nationwide, Ceil Power Systems are Australia’s forklift battery experts. To speak with a team member about your forklift battery and charging needs, call 1300 877 531 or contact us online.

Forklift Personnel Safety

As a practical material handling solution, forklifts are essential items of machinery in many Australian workplaces. However, care must be taken when operating a forklift, when working in areas in which they operate, and when maintaining the forklift. This includes charging the forklift battery. Today we take a quick look at staying safe around forklifts with some simple tips and a focus on forklift battery charging safety.

General Forklift Safety

When correctly maintained and operated in line with workplace health and safety guidelines, forklifts are safe machines to operate and work with. While accidents do happen, including fatal workplace accidents, most are caused by failing to follow OHS guidelines. Here are a few simple tips to reduce the likelihood of an accident.

Qualified operators only

To operate a forklift in Australia an operator must be qualified, which means they’ve completed the TLILIC2001 course. When a non-licensed driver operates a forklift, your business is at risk of serious fines and if an accident occurs there could be serious legal trouble ahead, including personal injury and workers comp claims.

Routine and scheduled checks

Forklift operators should give the machine a routine daily check to identify any faults or damage. Things to check include the tyre pressure, brakes, steering, mast and controls, all of which can be done in a minute or two before picking up a load. If any damage is identified, the forklift should not be operated until it’s repaired.

Safe and conscious operation

Most forklift accidents occur due to negligence and failing to follow OHS guidelines. Your forklift must be operated by a licensed operator, in an environment with clear visibility, at safe speeds, and in line with worksite and OHS rules. This involves keeping safe distances from workers, objects and other vehicles, allowing adequate stopping space, ensuring loads are stable and secure, and keeping people and objects clear of the mast.

Forklift Battery Safety

Following WHS guidelines is just as important when charging a forklift as it is when operating one in the workplace. Battery-powered forklifts are increasingly popular in Australian workplaces and whether a single machine or a fleet is employed, businesses need to create a dedicated space to recharge batteries when required.

Create a dedicated battery charging space

To provide a safe environment businesses need to create a battery charging space, ideally a room separated from other areas. Only licenced staff members should be allowed to access the space and charge the forklift batteries.

Acid-resistant flooring materials

Battery acid is highly corrosive and can cause structural damage if a major spill occurred. While unlikely, flooring in battery charging areas must be acid-resistant.

Natural and artificial ventilation

Hydrogen gas is released while charging forklift batteries which means ventilation is required to provide a safe working environment. Ideally a combination of natural and artificial (exhaust fans, vents, ducts, etc.) ventilation would be implemented.

Access to safety equipment

The correct personal protection equipment should be used when charging forklift batteries and safety equipment, including fire extinguishers, an eyewash station and acid-neutralising agents, should be immediately accessible.

Ceil Power Systems are Australia’s forklift battery experts. Call us on 1300 877 531 or contact us online to discuss your needs with one of our forklift battery and charging specialists. We operate locations in NSW, QLD, VIC and WA.

The forklift is one of the most versatile, hardworking vehicles in any industry.  Modern forklifts are workhorses with a lot of power, agility and excellent handling capabilities for loads and superior performance on the job.

There’s another side to this story – The modern forklifts are so good because they have excellent, highly efficient, high capacity power systems. They can deliver their fantastic lifting performance thanks to their big batteries.

Defining Good Forklift Batteries

A good forklift battery needs to meet certain expectations, such as:

  • being super tough and durable, made for years of hard work
  • incorporating modern systems, with chargers and maintenance accessories
  • meeting excellent charging capabilities, including monitored power curves, protective features, and more
  • having new power options, like traction batteries, power conversion and Multi-Frequency Chargers (MFCs) for “custom” charging needs

These new generation forklift batteries are real thoroughbreds; you’ll get excellent value and performance from them. That’s why you need to do your homework about choosing a new battery for your forklift.

Considerations include:

Adequate Power to Meet the Specifications of the Vehicle

To avoid getting lost in technicalities, the story here is that forklifts need power in accordance with their specifications. The battery has to be able to deliver the power profile for the forklift to work at peak efficiency.

Up-To-Date Batteries and Chargers

It’s impossible to overemphasise the importance of up-to-date equipment, including battery maintenance accessories. The old style batteries and chargers are effectively obsolete. You need the new user interfaces, programming capabilities and all the other innovative features – the new chargers are actually safer to use for operators and batteries.

Get Expert Guidance on Forklift Battery Selection

Before spending a cent on a new forklift battery, talk to your local forklift battery experts. This is the easy way to avoid any possible mistakes or problems with selecting chargers and battery maintenance accessories, too.

If you’re upgrading to a brand new forklift or new forklift fleet, expert advice will pay off well. Your experts will be able to help with battery selection to ensure that your new forklift is working at its best. They can also assist with the new technologies and new options for battery maintenance and performance management.

You’ll be saving money on battery operations and maintenance from day one. Better still, you’ll have expert technical guidance to help your people through the transition to your fabulous new forklifts. It’s a worthwhile precaution to get all the help and support set up while you do your acquisitions.

Like Some Technical Help with Forklift Batteries?

Ceil Power Systems can help you with forklift battery selection, operation, charging, maintenance, and all repairs and maintenance issues. Call us on 1300 877 531 or contact us online for fast responses when you need them as well as all the technical help, guidance and support you need for business operations.

Red and black electric forklift

Forklift operators are NEVER lazy about maintaining and looking after their machines. They do all their checks and respond quickly to any possible safety or operational issues. They keep track of any possible problems with their forklifts, and if they find problems, they get them fixed, fast.

If operators make any mistakes with forklift batteries, you can be sure that they’re honest mistakes. Highly trained and qualified forklift operators care about their work and their machines; if things go wrong, it won’t be their idea.

However, mistakes are inevitable. With modern forklift batteries and chargers, there’s a real learning curve in operational skills so we’re exploring the potential reasons for human error in forklift battery faults.

The Four Common Mistakes

The four mistakes can be basic or very complex, including:

1. Charging

Proper charging of modern forklift batteries is essential. These very powerful batteries need to be charged according to specifications. Operators need to monitor charging and deal with things like water and electrolyte solution levels.

If you’re thinking that list of things to concentrate on while charging means that there are more possibilities for mistakes, you’re quite right. One of the reasons modern battery chargers come with so many protective features is precisely because of these added risks.

2. The State of Repair and Battery Maintenance

Less excusable is the common issue of battery maintenance. Not maintaining your battery is like asking for an excuse to throw your hard-earned money out the window.

If maintenance hasn’t been done in the last year, your battery is likely to have developed at least a few minor issues. If those issues are allowed to get worse, you’ve got extra costs to deal with, perhaps major costs.

3. Lack of Training

Not exactly normal practice in the no-nonsense world of forklift operations, but lack of basic skills happens often enough. If an inexperienced or partially-trained person is working on a battery, you can expect problems. Even the most experienced of workers will inevitably make some mistakes.

Mistakes may include improper maintenance, charging issues and even serious safety problems with managing top-ups for electrolytes and watering. The quick fix is to make sure operators are supervised at all times during battery work. Fixing the problems that arise may require specialist services.

4. Older Batteries

Older batteries need extra care because they have a range of possible issues that vary in how commonly they occur. Problems may include stiff cables, for example, indicating old cabling which may be unsafe or underperforming. Corrosion is likely in this case. The smell of hydrogen sulphide tells you a battery has failed, but it should also tell you that you need help to deal with the situation.

The bottom line: The way to avoid mistakes is to call in the experts for regular maintenance. If there are big problems, your operators can’t fix them in-house, anyway. Your workers can learn how to avoid mistakes from the experts, an invaluable resource for your business.

Looking for Forklift Battery Experts?

Ceil Power Systems is your instant solution for forklift battery problems in Victoria, Queensland and New South Wales. Call 1300 877 531 or contact us online and we’ll help you with any problems. You can schedule regular maintenance services with us, too, to keep your batteries in great shape.

This issue is a bit trickier than it looks. There is a range of possible issues, and possible added costs, in deciding what to do. Today, we’re making a comparison between repairing and replacing forklift batteries so you can work out what’s right for you.

Forklift Battery Repairs

Forklift battery repairs may involve a range of problems. Older batteries may have multiple issues whereas large batteries often incur more complicated and expensive problems. Obviously, cost is a factor in deciding whether to repair or replace. Even with good prices, you may have to blink a few times if the repairs are likely to cost you a lot of money. Is it worth it?

In many cases, the cost of repairs will be worth the money. A good battery can be repaired back to excellent condition, good as new. That’s not quite the end of the story about forklift battery repairs, though.

Older forklifts typically have older batteries. It’s not at all unusual for an old forklift to find parts and components difficult to source, including their batteries. Forklift battery specialists can source batteries of all kinds, so you might be able to replace the faulty battery. If you can’t repair it, you might have to replace the forklift, not the battery. That’s the sort of unexpected cost most businesses could do without.

Forklift Battery Replacements

Forklift battery replacement is as straightforward as it sounds – you simply replace the battery. That’s not necessarily the end of the possible problems, though. What if the replacement battery is fine but there are still power issues with the forklift? What if there are transmission issues which were caused by system faults, not the battery?

Forklift battery power systems can be big problems, too. The old battery may have had issues but it may not have been the sole cause of power problems. The power systems may be more of a problem than the original battery issues.

You can see why it’s a good idea to consider both repair and replacement options – you really do have to cover all the angles. The old battery, if fixable, is the right battery for that forklift. The cost of replacement is avoided and your repaired battery will be fine.

The best practice approach to these issues is to get some expert guidance on your choices. Your forklift battery specialists will instantly find any power issues and be able to suggest a solution to get your forklift back in order. Downtime costs money, too, so this is the way to get things moving to a solution ASAP.

Need Some Help with Forklift Battery Problems?

Ceil Power Systems are experts in forklift battery repairs and replacement. We can help you to find the right solution and help with any problems you’re having with your power. Call us on 1300 877 531 or contact us online and talk to one of our friendly specialists about your forklift battery needs.

We are incredibly honoured and humbled!


For the 3rd Year in a row, CEIL Power Systems has been nominated as a finalist at the Australian Small Business Champion Awards, which is the pinnacle of small business success here in Australia.


As our Company continues to improve and grow, it is great to be noticed and rewarded for the hard work and effort that all of our staff put in daily to ensure our clients have well looked after. A big thanks to all involved who continue to support our Business here in Australia; we have an exciting future ahead for CEIL Power Systems, and our commitment to product quality and ongoing support underpins our success to date.


At Ceil Power Systems, your Trust and Quality in our brand is the absolute cornerstone of our Business as a whole. Today, the Excide Industries “CEIL” product is one of the worlds leading Industrial Battery products, and the trusted by many clients nationally and internationally. Our Motive Power products continue to supersede its humbling beginnings, and we are delighted to be announcing some huge news shortly that will only aid to reinforce why we are now considered Industry leaders with what we do.

Forklift Battery Chargers

Charging a modern forklift battery is precision work as these batteries need to be charged to their specifications in order to deliver the performance you need. You need a good charger to deliver the precision services you need. There are many types of battery chargers, and the new generation are far superior to old-style chargers, in ways that we are excited to explain here.

Types of Forklift Battery Chargers

The types of forklift battery chargers include:

  • Standard HF and transformer chargers – The new chargers in these ranges have easy-to-use interfaces, are programmable and deliver different power curves according to your needs.
  • Specialised chargers – These chargers include the revolutionary traction batteries, power conversion and new HF chargers with precision charging controls.
  • Multi-Frequency Chargers (MFCs) – The MFCs are the latest in forklift battery chargers, offering exceptional efficiencies. They incorporate power vs. speed configurations to manage charging times, built-in safety features, reduced water consumption features and a shopping list of other innovations.

Which Type of Forklift Battery Charger Do You Need?

The right charger will depend on the battery type to a large extent. Big batteries, for example, typically need a highly efficient charging regime. An MFC charger would be ideal for this type of battery, allowing both precision charging and improved efficiencies.

A smaller battery, however, may or may not need too many extra features; however, if you’ve got a brand new forklift, you’re strongly advised to get the best charger possible. These new forklifts are powerful beasts, and they need their power supply to be at its best.

The best way to find the right battery charger is to talk to the experts. You can speak directly to people who understand the issues with charging, and they can provide you with all the practical advice you need.

Having Issues with Your Charging?

Another major positive of talking to forklift battery specialists is getting useful information about battery issues. Do you have a battery that doesn’t seem to be fully charging? Does the battery need too much charging? Are you getting power issues in the forklift operations and you’re not sure if it is a fault of the battery? Is the power cutting in and out?

Problems like these won’t fix themselves. You’ll find that your forklift battery specialists will have an instant solution or an instant idea about what’s causing the problems. It’s a very efficient way of managing core assets like forklift batteries, which are the heart and soul of any forklift business.

Ask Us about Forklift Battery Chargers

If you’re looking for the latest forklift battery chargers on the market, Ceil Power Systems has the perfect solution for you. We have new battery chargers with all the new features. Call 1300 877 531 or contact us online and have a chat to our experts about your needs and any charging or power issues. We’ll be happy to help.

forklift battery maintenance

Forklift batteries are the motive power behind all forklift operations. If they have problems, so does your business. “Downtime” is a dirty word in the forklift business, and it’s also a very costly problem. We’re looking into the benefits of staying on top of your battery maintenance.

Forklift Maintenance Basics

The simple fact is that forklift batteries must be maintained well. Forklift batteries conduct a lot of power and work continuously for long periods of time. The level of wear and tear can be enormous. Corrosion, general system operations and the usual knocking around that forklifts take don’t help to keep the battery in good condition.

Routine maintenance is critical because the checking and managing of battery electrolyte levels must be done thoroughly. This work, however, isn’t enough to deal with potential problems in the battery – there might be component issues or hidden faults with the battery that could lead to failure down the track.

The essential point here is that your batteries will definitely need proper checking and maintenance over time. Just compare the costs of forklift battery repairs and battery replacement then project those costs over a year or two. Maintenance comes out as the much cheaper option, particularly for forklift fleets.

Getting Regular Forklift Battery Maintenance

Best practice for forklift batteries is much the same as all important pieces of equipment – don’t guess. Make sure the equipment is in good working order, and find problems before they cost you a fortune.

The best way to ensure you’re getting the maintenance and support you need is to schedule maintenance on a regular basis. You can pick and choose your times for maintenance to fit in with your operational needs.

Sourcing Forklift Battery Maintenance Services

Not surprisingly, the best forklift battery maintenance services are provided by forklift battery specialist companies. When you’re dealing with modern forklift batteries, you need specialists who are up to date with the latest technology.

If you’re a forklift business, it’s also good to connect with these specialist companies for useful technical help and support when you need it. Battery experts can deal with the most complex issues and offer an instant fix for a lot of problems to get your forklift back to work.

Your maintenance experts will also be able to deliver a fast response when you need one. You can avoid downtime costs with this type of service, and it’s always nice to know you can fix a problem with a phone call whenever you need.

Talk to Ceil Power Systems for Any Maintenance Work

Ceil Power Systems is your forklift battery specialist for any kind of forklift battery repair, maintenance and all the services your batteries need.  Whenever you want fast, expert help with your forklift batteries, just call 1300 877 531 or contact us online. We’ll set up a maintenance service for you, offer you a good price and be right there to deliver any help when you need it.

Forklift battery check

If you are experiencing issues with a big forklift battery, there are some serious risks involved in trying to fix it yourself. However competent you are, these big batteries come with potentially risky problems. We’re going to give you a few pointers to help you manage big battery problems.

The Problems

It’s just as well that modern forklift batteries are so reliable because if people had to handle them and work with them on a regular basis, it’d be a full-time job in itself. Big batteries are supersized and when they have problems, they tend to be supersized problems.

Battery maintenance is one thing. Most operators can do maintenance very well themselves. That being said, fixing big batteries is a very different ball game. Managing big batteries isn’t like managing smaller batteries on any degree of difficulty. The problems may include:


If you have to move a big battery for any reason, these very heavy batteries, like any big load, may have their own ideas about where they want to go. If a large forklift battery hits anyone or anything, there’s no escaping the damage. Trying to move a big battery through a busy workplace is also adds more risk during handling.

Heavy Batteries

Forklift operators are used to handling heavy loads, but batteries pack a lot of weight into a small space. Manual handling of these weights is a recipe for trouble and maybe a few months off work if you’re a little unlucky. This is why battery workshops are so well-equipped with handling gear.

Battery Chemistry

Batteries contain a cocktail of chemicals, including powerful acids. These acids are one of the reasons that all safety manuals recommend wearing the highest level of protection when working on batteries. Standard practice when dealing with battery acid is to use a neutralising agent to manage these acids if they get out for any reason. You can imagine what would happen without have a neutralising agent.

Risk of Damage to the Battery

Due to the handling issues, battery damage is a real possibility. There’s also the possibility of doing irreparable damage to an already faulty battery. Instead of fixing it, you may accidentally destroy the battery. Not exactly cost-effective, is it?

Unintentional Mistakes

You can’t fix a forklift battery by making the problems worse, either. These modern batteries are complex, precision instruments and you need a lot of knowledge to service them. If something goes wrong, you need someone who knows what has happened and how to deal with it. An innocent mistake can do a lot of expensive damage.

Looking for Expert Services for Your Batteries?

Ceil Power Systems provides a full range of repair and maintenance services for forklift batteries. If you have a big battery that’s causing problems and you’d like some assistance, call 1300 877 531 or contact us online. Talk to our experts, and we’ll be happy to provide any services you need.

Forklift battery check

Forklift batteries are designed to manage incredible workloads, and good batteries are great assets for any forklift business. That being said, when forklift batteries have problems, you need to identify them and fix them ASAP. If not, you could wind up with a major cost on your hands plus the added downtime expenses.

Forklift Battery Problems

Commonly occurring problems include:

Erratic Power

The forklift operates but shuts off, stalls or doesn’t power. This is a major issue. Don’t wait for another second, pick up a phone and get service immediately because these issues shouldn’t happen at all. The problem is almost definitely the battery and you’ve got a potentially dangerous machine to deal with. Take the forklift out of service until properly checked and repaired.

Short Battery Life

A truly infuriating problem, this is another issue your battery simply shouldn’t have. Forklift batteries are designed to deliver good working times. A battery which barely starts up before it shuts down is hardly performing up to specifications. There is nothing to do here besides picking up the phone and getting a service call booked. (A faulty charger may be the issue but you can’t take chances with this problem. Get everything checked to cover all angles.

Lift Problems

If your forklift is straining to lift a load, the fork isn’t getting enough power. It may hesitate, lift to a point, partially lift or stop; you’ll know that the power system and/or the battery are the problems here. The forklift must be taken out of service. It can’t be trusted to do the job, which is as good a reason as you could ever possibly want for getting service.

Combination Problems

There is any number of technical reasons for these problems, from battery points to mysterious electrolyte problems. The problems will happen, of course, when you’re extremely busy and don’t have two seconds free for the next six months. Don’t bother worrying; call for a service from a reliable specialist firm that knows you need everything done yesterday.

Nobody has ever called running a forklift business easy. There’s even a theory that there’s no such thing as pattern baldness in the forklift business because it’s caused entirely by operators and business owners tearing their hair out. Best practice for forklift businesses is to have the instant fix services available at all times to deal with the problems.

Need Some Help with Your Forklift Batteries?

Ceil Power Systems are forklift battery specialists. We know the problems. We already know you need your service ASAP or preferably sooner.  For any help you need with your forklift batteries, call us on 1300 877 531 or contact us online. We’ll deliver all the services you need.