Most electric forklifts run on a large traction battery, and changing one means lifting a very heavy, live battery out of the truck and setting it down without dropping it, damaging it or shorting it out. HSE's leaflet INDG139, Using electric storage batteries safely, sets out the main risks. This guide covers the right lifting equipment, preparation and the lift itself, and you can compare beams in our forklift battery lifting beams range as you go.
Why Battery Changing Needs Care
- Weight. HSE warns that batteries can be very heavy, and a forklift traction battery is far too heavy to lift by hand. Use lifting equipment rated for the battery's weight.
- Short circuits. HSE warns that metal tools falling across the terminals cause a short circuit. Lifting gear near the top of the battery carries the same risk, which is why HSE advises using insulated lifting equipment.
- Hydrogen. Batteries give off hydrogen and oxygen while they charge, so charging belongs in a dedicated, well-ventilated area.
Choose the Right Lifting Beam
A battery lifting beam hangs the battery from its lifting holes at the right spacing, so it lifts evenly without damage. Our beams are made to suit each battery, in three types:
- The conventional battery changing beam lifts on two twin-leg wire rope slings, with insulated webbing slings available.
- The insulated battery changing beam has four non-conductive slings, in line with HSE's advice on insulated lifting equipment.
- The low profile battery changing beam uses four short Grade 10 chains where headroom is limited.
All three slide onto your forks and are held with T-screw clamps. Each comes in 1000kg or 2000kg, with versions that can also hang from an overhead crane.
Prepare the Truck and the Area
- Change and charge batteries in the dedicated, well-ventilated area, and as HSE advises, don't smoke, do hot work such as welding or grinding, or use a mobile phone there
- Park the electric truck on level ground, switch it off, take the key out and disconnect the battery
- Take off watches, rings, chains, bracelets and other metal items, and keep metal tools off the battery
- Wear gloves and eye protection, preferably goggles or a visor, plus a plastic apron and suitable boots if you'll handle battery chemicals
- Have the stand or charging position for the battery clear and ready
Lifting the Battery Out, Step by Step
- Check the beam, slings or chains and hooks for damage, and check the beam's capacity covers the battery's weight.
- Slide the beam onto the forks and tighten the T-screw clamps.
- Bring the beam over the battery and hook every sling or chain into the lifting holes, with the safety catches closed.
- Check nothing metal can touch the terminals or connectors.
- Take up the slack, then lift slowly until the battery is just clear, and check it hangs level.
- Lift it clear of the truck, travel slowly with it low, and keep people well clear.
- Lower it fully onto the stand or charging position before you unhook it.
- Fit the charged battery the same way, then reconnect it.
Check the Lifting Truck's Capacity
The forklift carrying the beam lifts the beam as well as the battery, and both reduce what it can safely lift. Add the two together and check the total against the truck's capacity with the attachment fitted, using its capacity plate or figures from your supplier. Send us the details with your quote request and we'll help.
LOLER Checks
Battery lifting beams are lifting equipment, so LOLER requires regular thorough examination by a competent person, and lifting accessories such as slings and chains need one at least every six months unless an examination scheme sets a different interval. Check slings and chains for cuts, wear and damage before every lift.
Battery Lifting Beams at a Glance
| Beam | Lifts on | Best for |
|---|---|---|
| Conventional battery changing beam | Two twin-leg wire rope slings | Everyday battery changing |
| Insulated battery changing beam | Four non-conductive slings | Working close to the terminals |
| Low profile battery changing beam | Four short Grade 10 chains | Low headroom |
Need a Battery Lifting Beam?
Every beam is made for your battery, so request a quote with the distance between the lifting hole centres, the battery's width, height, lifting hole diameter and weight, plus your forklift make and model. Compare all three in our forklift battery lifting beams range. Moving gas cylinders too? Read how to move and lift gas cylinders safely, or browse everything on our forklift attachments page.
