LIFT TRUCK BATTERY CHARGING

OBJECTIVE

1. Responsibilities for checks

2. The basic components of the battery
3. Frequency and types of charge
4. General precautions and protective equipment
5. Documentation needed for the accurate recording of inspection
What is battery?

• Source of electric power consisting of one or

more electrochemical cells with external connections for
powering electrical devices.
Types of batteries
• Lead acid:
• cheap and have a good reputation for toughness and the most
common battery used in warehouses today
• Nickel cadmium:  
• perform well when they are not in use, holding their charge and
maintaining their voltage
• Lithium ion:
• more manufacturers recommend them over traditional lead acid
batteries.
• Main advantage is the speed they can take a full charge and they are
maintenance-free, and have a longer life
Basic components of the battery
Basic components of the battery
Frequency and types of Checks
Frequency and types of checks
• Check electrolyte levels.

• Check for proper cable polarity.

• Inspect cables for cut or torn insulation.

• Inspect contact tips.

• Inspect connector.

• Check for cracked or broken housing.

• Make sure all vent caps are securely in place.

• Ensure battery is free of any damages and is clean

Frequency and type of charge

• Recharge the Battery When It Reaches 20-30%  

Continuing to use a battery past 20% negatively affects its lifespan.
• Deep-discharging can cause electrical components to overheat and damage your
lift truck.

• Add deionized or distilled water frequently (check battery manufacturer

recommendations).
• Add water after charging - never before, and if you notice white crystals on the
lead plates, report the issue to the maintenance team.
Frequency and type of charge

• Always Allow Your Battery to Charge Completely

A battery has a limited number of charges in it. Partially charging
a battery still uses up a charge from its “bank.” 

• Avoid Extreme Temperatures

• Battery life can be reduced 50 % at 92 degrees.
• It’s performance drops  30 % at 30 degrees.
• In extreme temperatures, use a battery designed for those
conditions.
Frequency and type of charge

• Types of charges
• Conventional : battery is put it on its charger at the end of a shift
and resumes use in the truck when the battery is full.

• Fast :partially charging your forklift’s battery in a matter of 10-20

minutes, Charging rate 31-60 amps per 100 AH

• Opportunity : similar to fast charging and takes advantage of

breaks and shift changes to charge the forklift. Charging rate 21-30
amps per 100 AH
Precautions and PPE
• Charging battery poses safety risks involving sulfuric acid,
battery charging installations shall be done in designated
only and

• A Battery can weigh up to 3,000 lbs! Use equipment such as

a pallet jack equipped with a transfer carriage.
• No smoking, open flames, sparks or electric arcs in the
charging area.
• Tools and metal objects should also be kept away from the
tops of uncovered batteries.

• Face shield, rubber gloves and body apron should be worn