How to Maximize ROI on Electric Forklifts

Investing in new equipment comes with an expectation of strong ROI—especially when transitioning to electric forklifts. To maximize productivity and protect your investment, it’s essential to follow best practices that keep your electric fleet running efficiently. Below are key tips for improving performance, reducing downtime, and extending equipment life.

1. Avoid Over‑Discharging the Battery

Running an electric forklift battery below 20% state of charge can shorten battery life and cause electrical system issues. Excessive discharge may lead to:

• More frequent battery changes
• Slower workflow and reduced productivity
• Increased wear on battery components

Keeping batteries above 20% remaining charge helps prevent unnecessary downtime and costly repairs.

2. Use the Forklift Only for Intended Tasks

Electric forklifts perform best when used exclusively for lifting and transporting loads. Misusing a forklift—such as pushing materials, closing railcar doors, or towing—can overheat components and cause serious damage.

Potential consequences include:

• Overheating of electrical components like diodes and contactors
• Damage to traction motors due to high current demands
• Reduced battery run time
• Stalled motors and blown fuses
• Repairs not covered under warranty

Even a single instance of misuse can trigger overheating or component failure, resulting in costly downtime.

3. Match Forklift Settings to the Operator and Application

Many modern electric forklifts offer programmable performance settings that allow operations to tailor:

• Travel speed
• Acceleration
• Hydraulic response
• Regen braking levels

This customization helps balance productivity, safety policies, and operator preference—ultimately improving efficiency throughout your facility.

Electric Forklift Maintenance Tips

Although electric forklifts require less planned maintenance than internal combustion models, proper care is still essential. These maintenance practices help extend lifespan and maintain consistent performance.

1. Maintain Proper Battery Water Levels

Incorrect watering is one of the most common causes of reduced run times and battery overheating.

To ensure proper battery watering:

• Check water levels after charging, when the battery is cool
• Avoid under‑watering (causes heat and damage)
• Avoid over‑watering (dilutes electrolyte and reduces capacity)
• Create a watering schedule based on your fleet’s needs

You can determine the ideal schedule by checking cell water levels weekly and noting how long it takes for levels to reach the splashguards.

2. Charge Batteries Correctly

Improper charging can lead to wasted time, reduced battery life, and damage to the truck or charger.

Tips for correct charging:

• Train staff on proper charger connections
• Ensure chargers match the battery type
• Verify that connections go to the battery, not the truck

Correct charging habits significantly extend battery life and improve daily uptime.

3. Inspect Cables and Connectors Regularly

Every six months, include cable inspections in your maintenance routine.

Look for:

• Cuts
• Frayed wires
• Burn marks
• Loose or damaged connectors

Inspect chargers annually to prevent safety issues and ensure consistent charging performance.

Is an Electric Forklift Right for Your Business?

Electric forklifts offer numerous benefits, including reduced emissions, lower operating costs, and the ability to run extended shifts. When combined with proper maintenance and best practices, electric fleets can deliver exceptional ROI and long-term reliability.

If you need help implementing a maintenance schedule or optimizing your fleet, contact your local Jungheinrich dealer or material handling expert.