How to Charge a Forklift Battery

Last Updated: October 21, 2021

With more and more businesses switching from IC (internal combustion) forklifts to electric forklifts, new challenges are presenting themselves. This article will describe best practices around charging and maintaining a forklift's battery.

Steps

1
Be sure the charger is correctly matched to the battery. This means that the charger has the correct output voltage (12, 24 volt, 36 volt, 48 volt, etc). Also, the output Ampere Hour rating on the charger is closely matched (within 10%) of the AH rating of the battery.
2
Be sure the charger cables are not damaged or heat worn. The connectors should be in good shape, not damaged or cracked. Also, the connectors should not be burned or pitted and they make a good electrical connection with each other.
- If the lift truck consumes greater than 40% of the battery's charge at the end of the workday, the battery should be placed on charge for a full 8 hours.
- Batteries are watered after they are fully charged. The water should be distilled or free from heavy mineral content and the levels in each cell should be raised to just above the perforated grid. Do not overfill. Do not water an uncharged battery - it can overflow.
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3
Keep a watering log in case of a warranty claim. The manufacturer will want to see your watering records.
4
Charge the battery no more than 300 times a year for 5 years (1500 cycles) to not void the warranty.
5
Allow the battery to charger a full 8 hours through the gassing stage. This helps recombine the electrolyte (acid) throughout the battery and keeps the battery running optimally.
- The gassing phase or charging a battery produces oxygen and hydrogen. Never inspect a charging battery with an open flame. Never smoke around a battery. Charge the battery in a well ventilated area, never in a small room.
6
Equalize charge your battery once a week. This is a longer charging cycle and is often performed at the end of the week.

Community Q&A

Question

A Nissan electric forklift is leaking acid and smoking from the top of battery cells, what do I do?

Mzm555

Top Answerer

Immediately change the battery and dispose of the old one. Consult an authorized repair person for removal of old battery and refitting of the new battery.
Question

On a sit-down electric forklift, does the cover need to be open when charging the battery?

Mzm555

Top Answerer

Usually yes, to provide adequate ventilation, but also for the simple reason of letting operators see the forklift is charging.
Question

My lift batteries died and aren't charging, what do I do?

Mzm555

Top Answerer

Consult an authorized repair person/forklift mechanic who will diagnose what the problem is - likely the battery needs replacing.

Warnings

Never place metal objects on top of a forklift battery.

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Always use a battery service stand to inspect a battery. A forklift battery can weigh more than 2000lbs. It should be handled only with the greatest care.

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Never charge the battery near an open flame or spark.

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