How to Charge and Care for Forklift Batteries

When charging forklift batteries, it’s important to follow these simple tips to ensure the longevity and performance of your battery.

Keep your battery:

• Cool – Allow the battery to cool after charging to below 120°F before use.
• Clean – Clean, dry batteries last longer and experience fewer issues.
• Watered – Make sure the battery plates are covered with water, but avoid overfilling.
• Charged – Unless using specialized chargers, charge the battery no more than once every 24 hours.
• Discharged – Do not discharge the battery more than 80% (many forklifts have a lift interrupt feature to prevent over-discharge).
• Rotated – Rotate your battery fleet regularly if you’re operating in a multi-shift, multi-battery environment.

On a daily basis:

1. Inspect the batteries after a full charge and cooling period (typically 8 hours of charging and 8 hours of cooling). Check for frayed cables, broken connectors, or any other visible issues.
2. Ensure batteries are discharged to no more than 80%. Avoid using a boost charge during breaks to “trick” the forklift into thinking the battery has more energy than it does. This can damage both the battery and the forklift. Over-discharge leads to higher current flowing into the truck, which causes more wear on the electrical components.

On a regular basis:

1. Ensure that the battery and charger are properly matched. Just because the connectors fit doesn’t mean the charger output matches the battery’s DC voltage and amp-hour capacity. Have your sales rep perform an audit to confirm compatibility.
2. Water the battery weekly after a full recharge. The water level should be about 1/4″ below the vent well neck. Use demineralized or distilled water for best results.
3. Perform an equalizing charge once a week. Some chargers have this feature built in automatically. If unsure, check with your sales rep for guidance.
4. Clean and neutralize the batteries twice a year to prolong their lifespan.
5. At the same time, have a technician check the specific gravity, cell temperatures, and voltages for any issues.