Replacing an EP25-35CN forklift battery requires safety precautions, proper tools, and following manufacturer guidelines. First, power off the forklift and wear PPE. Use a battery cart or lift to remove the 1,500–2,000 lb battery. Clean terminals, inspect for damage, and install the new battery using alignment guides. Always follow OSHA-compliant disposal methods for old batteries.
What Safety Gear Is Required for Battery Replacement?
Wear insulated gloves, safety goggles, and steel-toe boots to prevent acid burns or electrical shocks. Use a face shield when handling corroded terminals. OSHA mandates flame-resistant clothing in industrial settings. Never skip PPE—battery electrolytes contain sulfuric acid, which can cause severe chemical burns.
For optimal protection, select gloves rated for chemical resistance (ASTM F696) and goggles with a ANSI Z87.1 certification. Flame-resistant coveralls should meet NFPA 70E standards for arc flash protection. In cases where batteries show visible cracks, add a rubber apron to your gear. Training on PPE usage reduces injury risks by 68%, per NIOSH data. Always inspect gear before use—frayed gloves or fogged lenses compromise safety.
| PPE Item | Purpose | Minimum Standard |
|---|---|---|
| Insulated Gloves | Prevent electrical shocks | Class 00 (500V) |
| Face Shield | Protect from acid splashes | ANSI Z87.1 |
| Steel-Toe Boots | Crush protection | ASTM F2413 |
How to Dispose of Old Forklift Batteries Properly?
Contact EPA-certified recyclers—lead-acid batteries are 98% recyclable. Never landfill: federal fines exceed $10,000 per violation. Return old units to dealers under “core charge” programs. Document disposal via manifests to comply with RCRA Hazardous Waste Regulations. Some states require separate battery recycling tax stamps.
Recycling centers typically extract lead plates, separate polypropylene cases, and neutralize acid. The average EP25-35CN battery yields 18-22 lbs of reusable lead. Core charge programs offer $150-$400 credit per returned battery. Always transport old batteries upright on spill-proof pallets—leaking units require DOT-approved containment vessels. Seven states mandate recycling fee payments:
| State | Recycling Fee | Documentation |
|---|---|---|
| California | $10 per battery | Form BAT-7 |
| Michigan | $5 per battery | EP-115 |
| New York | $15 per battery | DEC-3400 |
“The EP25-35CN’s design allows faster swaps than competitors, but technicians often overlook torque specs. Undertightened terminals cause 37% of premature failures. Always use a calibrated wrench and recheck after 24 hours of use.”
– Redway Power Systems Lead Engineer
FAQs
- How Often Should EP25-35CN Batteries Be Replaced?
- Every 1,500 cycles or 5 years, whichever comes first. Capacity below 80% warrants replacement.
- Can I Use Non-OEM Batteries in My Forklift?
- Yes, but ensure UL/CE certification and matching amp-hour ratings. Mismatched batteries void warranties in 89% of forklift models.
- What’s the Cost to Replace an EP25-35CN Battery?
- $2,800–$4,200 including core charge. Lithium-ion upgrades cost 2.3x more but last 3x longer.
