3 Possible Reasons Your Forklift Won’t Start

3 Possible Reasons Your Forklift Won’t Start

When you have loads to transport, a forklift that won’t start becomes a time-consuming hassle. The problem may lie in the battery or in the lift truck itself. Troubleshoot more efficiently by considering these three possible reasons your forklift won’t start.

Incorrect Battery Charging

Electric lift trucks rely on batteries for power, but poor battery charging causes a weak battery. The battery may charge incorrectly if it’s too old, has loose or corroded battery connections, or if there’s a problem with the charging system.

Causes of Inadequate Charging

Old batteries degrade and lose the ability to hold a full charge. Replace outdated batteries with new forklift batteries to regain full charge capacity and reliable performance.

Check the battery’s connections to ensure they aren’t loose or corroded. Make sure parts are secure and clean so electricity can flow uninterrupted during the charge cycle. Fully disconnect the battery and use a battery cleaner to remove any corrosion.

Finally, the charging system itself may have an issue. Sometimes, power outages or electrical surges during a charging cycle can prevent the battery from charging. Test the charger, visually inspect it for damage, and replace it if needed.

Cold Temperatures

Another possible reason your forklift won’t start is that the battery is cold. Lead-acid and lithium-ion forklift batteries work through electrochemical reactions. Cold weather slows these chemical reactions down, weakening the battery.

Low temperatures can greatly decrease the battery’s lifespan and run time, and you won’t get the best performance from the battery when temperatures drop below 60 degrees Fahrenheit. Limit exposure to cold temperatures during use and while the battery is in storage to maintain functionality.

Lift Truck Settings or Issues

Forklift settings or issues with the truck’s components may prevent it from starting. For example, after activating the emergency stop button, you’ll need to de-activate it before starting the forklift up again.

Warning lights on the dashboard can tell you the source of the trouble. The symbols signal the type of issue, while the light’s color indicates the problem’s severity. Consult your owner’s manual or the manufacturer’s website to understand the indicators on your model.

Improper battery charging, a cold battery, and issues with the truck itself can prevent a forklift from starting. Regular maintenance can help you avoid these issues, but if you experience a problem turning the forklift on, be sure to check for these common causes.

4 Common Forklift Battery Charging Hazards

4 Common Forklift Battery Charging Hazards

Electric-powered lift trucks reduce your business’s carbon footprint, lower noise pollution, and require less maintenance than gas-powered trucks. While electric forklifts provide many benefits, their charging stations present many possible dangers. Learn about four common forklift battery charging hazards to understand how to protect yourself and others.

Potential Crushing Injuries

Forklift batteries can weigh between 1,000 and 4,000 pounds, so trained operators use machines to lift and move the batteries for charging. Maintaining the battery-handling machinery will ensure predictable, smooth movements.

Improper manual handling can crush hands and feet or cause muscle strain. Train and retrain employees on how to operate the handling equipment to avoid these incidents.

Acid Exposure

Another common forklift battery charging hazard is acid exposure. Lead-acid batteries contain an electrolyte of sulfuric acid. Sulfuric acid is corrosive and can cause chemical burns.

Workers can protect themselves from sulfuric acid splashes by wearing acid-resistant gloves, goggles, face shields, and aprons. Additionally, employers must provide an eyewash station with at least 15 minutes of flowing water.

Tip: Clean Acid Spills Immediately

Acid spills can destroy surfaces and cause burns, slips, and falls. Wear PPE and use an acid spill kit to clean the spill immediately. The kit may include materials such as an acid neutralizer, an absorbent, brushes, disposal bags, and labels.


Overcharging can cause a forklift to heat excessively, which may lead to the battery catching on fire or exploding. Overcharging means continuously charging a battery that’s already at full capacity, which causes the electrical energy from the charger to convert into heat energy.

Never overcharge the battery. If you have problems charging your battery, or if the battery does not hold its charge, consider an electric forklift battery replacement. New and refurbished batteries charge safely and effectively.

Fire Safety Tip: Control Hydrogen Gas Accumulations

A spark source is extremely dangerous in battery charging stations. When batteries charge, they generate hydrogen gas, which is colorless, odorless, tasteless, and extremely flammable. Proper ventilation systems are essential for preventing hydrogen accumulation.

Electric Shock

Finally, improper handling can cause the battery to shock the worker. Only trained and qualified personnel should charge batteries.

Keep metal tools away from uncovered batteries. Also, employees should not wear metallic jewelry or other items that may conduct electricity.

Workers should never directly touch or use an object to touch the positive and negative terminals simultaneously. Doing so may cause a spark that ignites the hydrogen gas.

Avoid crushing injuries, acid exposure, fire, and electric shock by maintaining equipment and keeping personnel up to date on best practices. Shop with Green Power Forklift Batteries for lead-acid and lithium-ion batteries—our high-quality products keep your fleet powered and improve operational safety.

3 Benefits of Electric Forklifts Over Propane

3 Benefits of Electric Forklifts Over Propane

Electric and propane lift trucks are two popular alternatives to diesel-powered options. Electric forklifts commonly use lead-acid batteries, but lithium-ion batteries are growing in popularity. Propane forklifts, also called LPG (liquefied petroleum gas) forklifts, are powered by propane.

Your fleet’s power source affects the efficiency and cost-effectiveness of handling operations. Learn three benefits of electric forklifts over propane to understand how going electric can help your business.

Reduced Environmental Impact

Propane forklifts emit harmful pollutants and greenhouse gases during operation. In contrast, electric forklifts produce zero tailpipe emissions, making them a more eco-friendly choice.

This difference is particularly important for indoor operations where poor air quality can negatively affect workers’ health. By switching to electric forklifts, companies can reduce their carbon footprint and create a healthier working environment.

Propane and Carbon Monoxide

When propane combusts completely, it produces carbon dioxide and water. However, incomplete combustion yields carbon monoxide, a toxic gas that interferes with the ability of red blood cells to carry oxygen. Headache, fatigue, and dizziness may indicate overexposure and inadequate ventilation of carbon monoxide.

Lower Total Cost of Ownership

Another benefit of electric forklifts over propane is the lower total cost of ownership. LPG forklifts cost less upfront. But within about two years, an electric forklift will offset the initial cost difference. That’s because electric forklifts have lower energy costs and operation and maintenance (O&M) costs.

Your forklift’s specifications affect the cost of ownership. Brand-new, standard-capacity electric forklifts often cost between $20,000 and $45,000. Batteries for forklifts—whether lead-acid, lithium-ion, new, or refurbished—also affect the overall cost.

Quieter and Smoother Operations

Finally, electric forklifts operate much more quietly and smoothly than propane lift trucks. The reduced noise level can improve working conditions for employees, improving workplace satisfaction and productivity. Quieter operations can be particularly advantageous in indoor operations.

Electric forklifts don’t vibrate as much as LPG forklifts. Reducing vibrations can decrease worker fatigue, improving how operators handle the lift truck and reducing the risk of injury or product damage.

Electric-powered lift trucks have a lower environmental impact, lower total cost of ownership, and provide more operator comfort compared to propane forklifts. Shop with Green Power Forklift Batteries for new and reconditioned industrial batteries that improve the efficiency of your business operations.

The Differences Between Lithium-Ion and Polymer Batteries

The Differences Between Lithium-Ion and Polymer Batteries

Lithium-ion technology is popular in modern batteries thanks to faster charging times and higher power density. Lithium-ion and lithium polymer batteries are two common types of batteries that use lithium-ion technology. Learn the differences between lithium-ion and polymer batteries to understand how each option performs.

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Are Lithium Batteries Better Than Lead-Acid for Forklifts?

Are Lithium Batteries Better Than Lead-Acid for Forklifts?

Choosing a forklift battery is a key consideration for maximizing efficiency, improving productivity, and controlling costs. Lead-acid and lithium-ion batteries are two prominent options for powering forklifts. Compare performance, maintenance, lifespan, and environmental impact to determine whether lithium batteries are better than lead-acid for forklifts.


Lead-acid batteries provide reliable performance and can deliver high initial power output. However, lead-acid batteries have lower energy density than lithium-ion batteries, resulting in shorter run times and increased weight. They also exhibit voltage drop as they discharge, reducing performance over time.

Lithium-ion batteries have a higher energy density, allowing for longer run times and reduced weight, which can enhance forklift maneuverability. The voltage of lithium-ion batteries decreases at a less noticeable rate than lead-acid alternatives. Plus, lithium batteries have faster charging times, which minimizes downtime and can increase overall productivity.

Performance Winner: Lithium-Ion

Lead-acid has been the traditional power source for forklifts and is still a reliable choice. But if you want better performance, go with lithium-ion batteries.

Maintenance and Lifespan

Lead-acid batteries require watering, equalizing charges, and periodic cleaning. Proper maintenance is crucial to prevent sulfation, which is the buildup of lead sulfate crystals that can significantly reduce battery performance and lifespan. Lead-acid batteries can last through 1,000 to 1,500 charge cycles.

In contrast, lithium-ion batteries do not require watering or equalizing charges. Minimal maintenance requirements reduce labor and costs associated with battery upkeep. Moreover, lithium-ion batteries may last for 2,000 to 3,000 charge cycles.

Maintenance and Lifespan Winner: Lithium-Ion

Lithium-ion batteries require less maintenance, making everyday workflows more efficient, minimizing downtime, and improving worker safety. The significantly longer lifespan of lithium-ion also helps offset its higher purchase price.

Environmental Impact

Another factor to consider when determining if lithium forklift batteries are better than lead-acid is each battery’s environmental impact. Improper disposal or recycling of lead-acid batteries can lead to soil and water pollution. However, lead-acid batteries have a high recycling rate, and responsible recycling practices mitigate their environmental impact.

The higher energy efficiency of lithium-ion batteries results in lower greenhouse gas emissions. However, the amount of energy used to keep the battery charged, called the operational cost, is about the same because lithium-ion batteries include a battery management system.

Lithium-ion batteries contain fewer toxic substances. Like lead-acid, lithium-ion batteries are recyclable, although presently, lead-acid batteries have a higher recycling rate.

Environmental Winner: Lithium-Ion, Probably

Overall, lithium-ion batteries are more environmentally friendly than lead-acid. However, technological advancements continue to improve lead-acid efficiency, and refurbishment significantly increases lead-acid’s reusability.

Lead-acid batteries offer reliable performance and are cost-effective for applications that do not require extended run times or fast charging. On the other hand, lithium-ion batteries provide higher energy density, longer run times, faster charging, and lower maintenance requirements.

At Green Power Forklift Batteries, we carry lithium-ion batteries as well as new and refurbished lead-acid batteries. Whatever your budget or efficiency considerations, buy forklift batteries from us for high-performing power.

The Difference Between Electric Forklift Weight and Capacity

The Difference Between Electric Forklift Weight and Capacity

A forklift’s weight and capacity seem similar, but they refer to different measurements. The forklift weight is the vehicle’s weight, while the lift capacity is how much weight the truck can carry.

Weight and capacity are two important characteristics that affect how you should operate a forklift. Learn more about the difference between electric forklift weight and capacity.

Forklift Weight

As stated, forklift weight is the vehicle’s weight. The weight can vary between different models, but forklifts usually weigh between 3,000 and 20,000 pounds because they contain heavy-duty materials, such as steel. They also have a heavy counterweight at the rear to maintain balance when carrying a load.

Does the Weight Include the Battery?

Data plates on lift trucks list the total truck weight, including the battery, while others exclude the battery’s weight. Electric forklift batteries can range from 1,000 to 4,000 pounds, so it’s important to know whether this amount is included in the data plate table.

Forklift Capacity

Forklift capacity is how much weight the forklift can carry; exceeding the truck’s capacity can cause it to tip. Low-capacity machines can handle about 3,000 pounds, while high-capacity models can carry over 50,000 pounds.

Read the forklift data plate to determine the vehicle’s load capacity. The rated load capacity is the maximum amount the forklift can handle under optimum conditions. However, several factors can lower the weight the truck can actually lift.

Rated Load Capacity vs. Actual Load Capacity

Sometimes, the rated load capacity is higher than the actual load capacity. Factors that affect load capacity include the following:

  • Lift Height: The higher you raise the forks, the lower the load capacity.
  • Attachments: Attachments can change the forklift’s center of gravity.
  • Forklift Condition: Wear and tear will lower the machine’s load capacity.
  • Load Center: Load capacity diminishes if the load is not centered.

Understanding the difference between electric forklift weight and capacity will help you prevent injuries, property damage, and problems such as tip-overs.

Power your lift truck with a reliable forklift battery for the best performance. Green Power Forklift Batteries carries 36-volt forklift batteries from commended brands, so shop with us today to optimize your material handling!

Forklift Battery Mistakes To Avoid at All Costs

Forklift Battery Mistakes To Avoid at All Costs

Forklift batteries allow lift trucks to lift and maneuver material handling loads. Well-maintained batteries are crucial for efficient operations, but improper battery care can create a financial burden and safety hazards.

Ensure the longevity and optimal performance of your forklift battery by understanding these forklift battery mistakes to avoid at all costs.

Charging Incorrectly

Incorrect charging affects battery performance and can lead to irreparable damage. Overcharging, undercharging, and quick charging are three actions that can cause problems for your battery.


Overcharging a forklift battery can cause excessive heat buildup, damaging the plates and shortening the unit’s lifespan. Follow the manufacturer’s guidelines regarding charging times to prevent overcharging.


On the other hand, undercharging a battery can reduce its capacity, negatively impacting the forklift’s operating time. Frequently undercharging increases the number of recharges and wear on the battery.

Fast Charging

A fast-charge cycle takes 10 to 30 minutes, which is convenient for heavy-use operations. But you must calculate if the convenience of quick charging is right for your business because the method of charging wears the battery down much faster than conventional charging.

Mismatching Charger and Battery Voltages

Another forklift battery mistake to avoid at all costs is mismatching the charger and battery voltages. Using the incorrect charger for the battery can severely damage the equipment and create safety hazards.


Using a charger with a higher voltage than the battery’s specifications can cause an excessive charging current. Overvoltage can lead to overheating, electrolyte loss, and potential damage to internal battery components.


Using a charger with a lower voltage may not provide sufficient power to fully charge the battery, reducing performance and shortening the battery’s lifespan. Verify that the charger’s voltage output matches the battery’s requirements to avoid undercharging.

Allowing Lead Sulfate Crystals To Build Up

Finally, lead sulfate crystals can accumulate on the battery, hindering its performance or putting it out of commission. Minimize the buildup of lead sulfate crystals by charging the battery correctly and with these additional maintenance tips.

Inspect and Clean the Battery

Inspect the battery for any signs of sulfate buildup. Regularly clean the battery to prevent the crystals from hardening and damaging the battery plates.

Water the Battery

Maintain correct water levels in the battery to ensure optimal electrolyte density and reduce crystal formation. Typically, batteries require watering about once a week if used daily, but you should check them after every five charges. Add water to a forklift battery after it is completely charged to avoid overflow.

Visit Green Power Forklift Batteries when you need a replacement forklift battery. We offer new and refurbished batteries for various lift truck types and brands. Find a reliable power source when you shop with us today.

How To Read—and Understand—an Electric Forklift Data Plate

How To Read—and Understand—an Electric Forklift Data Plate

When operated correctly, electric forklifts handle heavy loads safely. Read the truck’s data plate for information such as its weight and load capacity. Learn how to read and understand an electric forklift data plate.

Model Number and Serial Number

Knowing the model number is essential for dealers or service workers repairing or performing maintenance on the machine. You will need to know this number to get the right replacement parts, such as a new or refurbished forklift battery. The serial number uniquely identifies the forklift and is especially useful for technicians to understand the machine and its maintenance history.


The data plate indicates the forklift’s weight, which is important for calculating the weight of the load the forklift can safely carry. Note that the weight on the data plate does not include the battery’s weight. If you need to know the total weight of your lift truck, add the listed weight on the data plate to the weight of the battery.

Mast Type and Back Tilt

The forklift mast lifts, lowers, and positions the load. The back tilt means how far backward the mast can tilt. The value shown on the nameplate is in degrees. Here are the most common mast types and what they might be called on your data plate:

  • 3-stage: sometimes called FSV or TSU
  • 2-stage: V or FV
  • 4-stage: QFV

Rated Load Capacity Chart

The rated capacity of the forklift truck is printed on a table on the nameplate. Factors such as the truck’s load center, maximum lift height, and attachments affect the weight of the load the truck can handle.

The table will show the lift truck’s load center, or the distance to the center of the load’s gravity from the front and top of the forks. It will also show the maximum lift height, or how high the forklift mast goes. Finally, the table shows the load capacity based on the load center, maximum lift height, and installed attachments.


Installed attachments are listed on the lift truck’s data plate because the attachment reduces the lift capacity. Attachments also have their own data plates.


Nameplates include information on the front tire tread, the tire type, and size. The front tread value indicates the width of the front wheels. The word “solid” in the tire information section indicates the truck requires cushion tires. Otherwise, the nameplate will show the recommended PSI for air-filled tires.

Knowing how to read and understand an electric forklift data plate makes operating and maintaining the truck safe and easy. When it’s time to replace your industrial forklift batteries, shop with Green Power Forklift Batteries for new and refurbished units. Contact us today for a reliable power solution!

4 Tips To Get the Most Out of Your Forklift Battery

4 Tips To Get the Most Out of Your Forklift Battery

Proper maintenance protects forklift batteries and ensures you get the most use out of your equipment. Taking care of the battery improves its performance and saves your business money. Use these four tips to get the most out of your forklift battery.

Charge Correctly

Only charge your battery once it is depleted to 20–30 percent of its charge capacity. If you charge before it reaches 30 percent, you will shorten the battery’s lifespan. And using the battery after it has less than 20 percent charge will increase wear on the unit.

Completely charging a lead-acid battery takes about eight hours. After charging, let your battery cool for the manufacturer’s recommended amount of time before use—typically another eight hours.

Add Water As Needed

Maintaining the electrolyte level is key for getting the most out of your forklift battery. Typically, batteries require deionized water, but you should follow your manufacturer’s instructions to be sure. Watering will keep the electrolyte at the right acid-to-water ratio.

Only water the battery at the end of the charge cycle. Watering before or during the charge cycle increases the chance of a boil-over, pushing hazardous sulfuric acid outside the battery.

Store in Safe Conditions

Proper battery storage protects the equipment’s working lifespan. Prevent sulfation by fully charging the battery and adding water before storage. Store in a dry location and ensure air can circulate around the battery. Protect the top of the battery from dust and debris.

Generally, you should store forklift batteries at temperatures between 60 and 80 degrees Fahrenheit. Do not place batteries near sources of heat, such as radiators.

Recondition the Battery

Finally, forklift batteries have an average lifespan of about five years or 1,500 charge cycles. Workloads and battery maintenance affect how long your battery will operate. Fortunately, once your battery reaches the end of its initial lifecycle, you can have it professionally reconditioned to give it a second life.

At Green Power Forklift Batteries, we use an 18-stage reconditioning process to maximize the functional lifespan of batteries and ensure high performance. Contact us for more information on how refurbished forklift batteries can benefit your business.

Effective Ways To Improve Your Material Handling Efficiency

Effective Ways To Improve Your Material Handling Efficiency

Material handling efficiency improves customer satisfaction, lowers overhead expenses, and increases revenue. Read to learn effective ways to improve your material handling efficiency.

Minimize and Improve Manual Handling

Manual handling is when workers move and handle products by lifting, holding, carrying, pulling, and pushing. Risk factors of manual material handling include forceful exertion, high repetition, and sustained awkward postures that put stress on joints and muscles. When possible, handle materials with machines rather than manually to reduce worker risk.

Give workers adequate breaks throughout the day to reduce fatigue. Workers should use the right form when lifting and moving packages and avoid bending and twisting when they lift.

Improve the Warehouse Layout

Improving the warehouse layout will help optimize workflow. The better organized your warehouse, the more efficiently workers can move.

You will need to use different techniques to optimize individual areas of your warehouse. For example, you should maximize your use of vertical space for storage. But you can improve the use of the staging area by receiving goods during one shift and shipping them during another.

Maintain Equipment

Another effective way to improve material handling efficiency is to maintain equipment. Schedule maintenance to minimize disruptions to your routine. A maintenance schedule will ensure you promptly inspect, adjust, and repair equipment.

Docking, storing, lifting, and packing equipment make it safer and easier to handle materials. Maintaining equipment throughout your facility extends your machines’ life spans and helps prevent the need for expensive repairs.

Optimize Workflows

Assess workflows throughout your facility to find opportunities to optimize workflows. You might discover simple changes make a big difference. For example, opportunity charging forklift batteries during natural breaks in the operator’s shift can save time on charging and changing out the battery.

Get the most work out of your lift equipment with batteries from Green Power Forklift Batteries. We carry a range of industrial brands, including Toyota forklift batteries. Shop with us today for new and refurbished batteries.