Safety Precautions While Charging Your Forklift Battery

Safety Precautions While Charging Your Forklift Battery

Electrical safety on the job goes deeper than simple common sense. What may seem like an everyday task can quickly turn dangerous without the proper considerations and efforts. Besides basic safety when handling structural wiring components, employees must be aware of standard electric equipment, such as forklifts and their associated components. It’s your job to ensure you take the proper safety precautions while charging your forklift battery. Failure to do so puts fellow workers at risk in the worst-case scenario. And at best, it may ruin the battery and waste company assets.

Utilize the Correct Safety Equipment

When handling electrical equipment, it’s important to don the correct personal protective equipment. The amount of coverage necessary depends on the degree of work you plan to conduct. For handling batteries of any type, hand, arm, and face coverage is the bare minimum. In the case of electric batteries, choose rubber insulating gloves to prevent shock. Rubber insulated sleeves and shoulders effectively ensure accidental contact with the upper arms doesn’t result in injury.

As with anything involving acids, protective face gear is critical. In particular, you should protect your eyes against splashes with safety glasses or something even more robust. Ideally, you should wear a hard hat with an accompanying face shield. Besides this, managers and business owners should ensure they purchase the correct equipment. For example, choose only forklift truck batteries for sale from reputable dealers and refurbishing businesses and select only the corresponding charging equipment.

Be Aware of Conductive and Flammable Materials

Another crucial safety precaution while charging your forklift battery is to mind potentially hazardous elements. As a general rule, you should remove conductive metals from yourself while handling electric batteries. Personal effects, such as jewelry, can lead to accidents while this task is underway. Likewise, keep batteries clear of areas with exposed conductive metallic or flammable components.

A cement or brick space is ideal, so long as the area can maintain a regularly cool temperature. It should also be free of regular exposure to UV rays or excessive direct sunlight. Flame-resistant personal protective gear should be available to accommodate anyone with additional concerns.

Use Battery Charging Best Practices

As noted, using the correct equipment is vital for battery safety. Although some batteries may look alike, there are subtle differences that make different parts not wholly compatible. Always choose the battery that corresponds to the forklifts you use at the business. Likewise, only utilize matching charging equipment with the correct battery.

If multiple battery types are necessary at one location, organizing is key. Separating batteries and their matching equipment into different areas will help ensure confusion and accidents don’t occur. Lastly, forklift batteries make use of water to function correctly. You must restore their water levels with deionized water before using them. However, don’t refill batteries before charging them.

Maintenance Tips to Extend the Life of Your Forklift Battery

Maintenance Tips to Extend the Life of Your Forklift Battery

The forklift is one of the essential tools in the arsenal of warehouse workers. Often what goes wrong with these machines is a fault in the battery. Without a functioning forklift available, work quickly becomes backed up while the crew scrambles to find the solution. By using these maintenance tips to extend the life of your forklift battery, you can rest easy, knowing your forklifts will always be at the ready.

Store the Battery Properly

Believe it or not, batteries are not as durable as they immediately appear. Whether it’s a tiny coin cell battery or a full-sized forklift battery, they all require the same care and consideration. Like many relatively delicate items, it’s important to store the battery in a cool and dark space. Most importantly, batteries in storage should be kept at a relatively moderate temperature. Changes in light, the intrusion of extreme hot or cold weather, and of course, moisture all will negatively affect the lifespan of a batytery6 before it can even be used.

Watch the Water Levels

Forklift batteries are a little more complex than the average variety. Many different types require the manual addition of fluids, namely water. It’s essential that much like a car’s cooling system, these fluids are regularly checked and maintained. The best maintenance tips to extend the life of your forklift battery are those surrounding good upkeep habits. Create a routine to regularly check and top off the water levels in your batteries.

Regularly Clean the Batteries

The same as with any vehicle or heavy machinery, batteries are subject to the hassles of aging. Most notably, aging batteries often begin to show signs of corrosion. Besides being unsightly, the acidic corrosion is not especially safe to leave be. Too much corrosion will cause a permanent degrading of the battery by reducing the power output substantially. What’s more, given enough time, corrosion will cake onto the terminals of a battery. Severely corroded terminals may not spark at all, rendering the battery unusable until forklift battery suppliers properly refurbish it.

Only Use Corresponding Equipment

Another key element to protecting a battery is to ensure only matching equipment is ever used with it. While it might be tempting to grab any available charger, it should be noted using the wrong specifications will cause problems. While chargers might all look alike, few manufacturers have exactly matching components. Besides potentially bending or breaking the battery’s charging or terminals, it can also shorten a battery’s life. The wrong voltage or imbalanced charge due to incorrect plugs may even burn up a battery altogether.

How Long Should a Forklift Battery Last?

How Long Should a Forklift Battery Last?

“How long should a forklift battery last?” is sadly a question that people often only ask once the battery stops working. Without knowing the expectations of your business’s models and how to care for them properly, batteries will seem to die at unpredictable times. To ensure your warehouse always has the power it needs, you should know what your battery can handle and what to do when it finally ceases to function.

The Average Lifespan of Forklift Batteries

Every battery, regardless of the type or make, comes with an expected lifespan. Ultimately, a battery might not last as long as this estimate, or it may last longer, depending on how you handle it and the workload it must deal with regularly. To determine how long a forklift battery should last, first check the information the manufacturer provides. For the most part, the average lifespan of this type of battery is about five years. As noted, though, this period will vary dramatically for operations with heavier or lighter work expectations.

Reviving Batteries With Refurbishing

Once a battery finally dies, it’s not entirely junk from that instant onward. It’s possible to revive batteries through refurbishing techniques. However, forklift batteries differ from the average lead-acid batteries in cars and other large machines.

To bring one back, professionals must carefully balance the water to acid ratio, among other details. But on the other hand, refurbished batteries are just as reliable as new ones. Furthermore, refurbished electric forklift batteries for sale often come at a better bargain and result in less environmental pollution.

Maintaining Batteries for Optimal Lifespans

Treating a battery right will ensure a battery will reach its optimal lifespan, and refurbishing can extend its use even further. Improper care can and will drain your battery more rapidly and cause unnecessary damage. It may also result in premature failure. It’s necessary to store batteries in a cool and dry place.

Avoid overcharging and allow the batteries to drain through use before recharging them naturally. Forklift batteries require you to maintain their water levels. So, it’s beneficial to create a routine around checking and performing this task. Finally, it helps to keep a close watch for leaks and signs of corrosion. Regularly clean and maintain terminals of corrosion to ensure a consistent connection.

Warning Signs Your Forklift Battery Needs To Be Replaced

Warning Signs Your Forklift Battery Needs To Be Replaced

When there is heavy lifting and high places involved around the warehouse, a forklift is a must. As one of the primary tools of logistical work, forklifts need to be kept in good working condition by the company that employs them. One of the most unnecessary disappointments a worker can encounter on the warehouse floor is a malfunctioning forklift. 

Failures with critical equipment can easily set a schedule back hours and lead to incomplete tasks at the end of the day. What’s more, ignoring these warning signs your forklift battery needs to be replaced often leads to surprise expenses or even damage to the forklifts.

Decreased Use Times

One of the earliest signs of battery failure is a forklift that needs more time charging. Every battery should last for the duration that is typically indicated by the type and model. As the battery ages, that usage time window begins to shrink.

A machine that may have lasted an entire eight-hour shift might start needing a boost charge during breaks, lest it stops halfway through the day. If your forklift maintains the same load of work each day but increasingly indicates low battery, chances are it’s time to consider a replacement. For businesses on a budget, refurbished forklift batteries are an affordable and greener option than buying all-new.

Signs of Leaks and Damage

The worst warning signs your forklift battery needs to be replaced are those that point to severe damage. Old batteries can and will fail, sometimes in dramatic ways. The most common clue your battery needs to be replaced immediately is heavy corrosion on the terminals. The presence of this residue can impact the battery’s ability to be sparked.

After this, batteries may leak dangerous acids and will need to be removed and contained quickly. Sadly, any battery that’s reached this level of decay can’t wait any longer. Emergency replacements are rarely convenient, so maintaining a regular schedule to check on battery health is always helpful to any dynamic business.

Dramatic Power Reduction

Another strong indicator of battery failure is a power reduction. After using a forklift for a few days to a week, an entire team will quickly become accustomed to the speed and strength of each machine. Even those working alongside the forklift will easily be able to spot changes in performance. The keenest of the team may even hear down-pitching of the forklift’s normal operating sounds.

A battery beginning to show its age and a loose charge will dramatically affect how a forklift sounds and operates. The machine will move noticeably slower and will struggle to lift loads it used to handle with ease.

How To Select the Right Battery For Your Forklift

How To Select the Right Battery For Your Forklift

Selecting a battery for your forklift is a more complicated process than you might think, especially because—believe it or not—a forklift battery serves more than one purpose. Further, there are also several types of forklift batteries available on the market. So, you’ll need to know what each type does to make the right decision for your forklift fleet. Fortunately, we can aid you in the selection process. Below, we break down how to select the right battery for your forklift.

The Dual Purpose of Forklift Batteries

As previously mentioned, forklift batteries serve two essential purposes. The first and most obvious one is to provide a source of power for your forklift. The second and least apparent one is to serve as a counterweight. The battery’s mass aids the lifting capacity of the forklift and promotes overall stability. Thus, you need to select the right size of battery that will support your forklift. If you buy a battery that’s too small, your forklift could suffer stability issues.

But how do you figure out the right size for your forklift? First, check the forklift’s data tag to view the counterweight requirement, then measure the available space in the battery compartment. Once you have both metrics, you’ll know the exact size that you need for your forklift.

Electric Forklift Battery Types

Once you determine the correct size, you’ll need to decide which type of battery you need. Almost all electric forklifts in operation today use one of two main battery types. They are lead-acid batteries and lithium-ion batteries.

People typically consider lead-acid batteries an older technology. These batteries are bulky and contain tons of liquid. They generate electricity via a chemical reaction of lead plates and sulfuric acid. Lead-acid batteries require you to refill them with water frequently. On the other hand, lithium-ion batteries feature newer technology. Additionally, the battery cells are sealed shut, so you don’t need to fill them with water. Lithium-ion batteries also require far less maintenance than lead-acid batteries. Overall, lead-acid batteries are a bit old-fashioned, but they’re an inexpensive option. Lithium-ion batteries are reliable but can be on the pricey side, so you must consider your budget when buying batteries.

While these two are the most popular, they aren’t the only options out there. Propane is an option, as is diesel fuel, but these are scarce. They also have disadvantages when compared to lead-acid batteries and lithium-ion batteries.

We hope our insight on how to select the right battery for your forklift willhelp you in purchasing what’s best for your needs. Ready to shop? Green Power Forklift Batteries offers new forklift batteries in all types and sizes. For more information about what we have to offer, don’t hesitate to contact us.

Practical Ways To Improve Forklift Efficiency

Practical Ways To Improve Forklift Efficiency

Operating a forklift brings with it many responsibilities. Regular maintenance is crucial, but it doesn’t have to be complicated. With these practical ways to improve forklift efficiency, you can easily keep your vehicle up to standard.

Be Meticulous With Daily Inspections

OSHA already requires that you perform a thorough inspection of your forklift before each time you operate it. Keep it clean and remain on the lookout for problems such as uneven fork alignment, fluid leaks, soft brakes, or excess water in the battery. Attention to detail during inspections prevents safety concerns later!

Collaborate With Others

Even an experienced forklift operator can miss potential problems during a routine inspection. If you’re ever unsure during your inspection, or if you spot something unusual and cannot diagnose the issue, a second or third pair of eyes can ensure that the forklift is in proper working condition before you operate it.

Take Care of Your Battery

Forklift batteries require a delicate balance of fluids to work. Water the battery about every ten uses and take care not to overfill. Rinse away excess battery acid to prevent corrosion. If the battery is already corroded, or if it emits smoke and/or a rotten-egg smell, you will need to install a replacement forklift battery before you operate it again. Green Power Forklift Batteries offers a wide selection of new and refurbished batteries.

Get Comfortable

Do you feel fatigued or stiff after using your forklift all day? Ergonomic accessories and attachments can make forklift operation easier on your body. You should replace the seat at least every three years. A forklift positioner will shift your alignment hydraulically, saving you excess manual labor. You can more easily operate and maneuver a forklift if you’re physically comfortable.

A forklift is an essential tool in a warehouse environment and one that needs regular care and maintenance to operate at its full capacity. A few practical ways to improve forklift efficiency will ensure that both you and your forklift remain up to par.

All About Forklift Battery Chargers

Refurbished Forklift Batteries

All About Forklift Battery Chargers

Charging a forklift battery used to be a somewhat risky endeavor – the person doing the charging was also responsible for setting the amperage and voltage, and it was always possible that they would make a mistake. This could result in accidental overcharging, which could damage the battery and even start a fire.

That’s no longer the case with the newer forklift battery chargers. The newer chargers come with safety parameters built in, which will stop them from charging and show an error code rather than allow overcharging to happen. Despite this important new safety feature, they still allow a fair amount of control. You can set the charging time, the voltage, and the amperage, giving you the flexibility you need without the risk of making a costly mistake.

Buying a Charger

Forklift battery chargers generally cost anywhere from $500-$3000, with the price depending on the size of the charger. The small portable chargers cost the least, while the more expensive chargers actually have to be wired into the electrical system of the building by an electrical contractor.

When you’re buying a forklift battery charger, there are a few things you’ll need to check. One is the voltage of the battery you need to charge, as the charger will need to be the same voltage. The charger also needs to match the line voltage at the location where you plan to be using the charger. In addition, you’ll need to know the AH or amp hours rating of the battery, as well as whether the electricity phase is 1 Phase or 3 Phase.

Keeping your forklift battery properly charged will extend its lifespan, but all batteries need to be refurbished or replaced eventually. When you need to replace yours, you can sell it to Green Power Forklift Batteries and replace it with a new or refurbished forklift battery. We’ll get you whatever battery you need to keep your forklift running!

Anatomy of a Lead Acid Battery

Refurbished Forklift Batteries

Anatomy of a Lead Acid Battery

If you’re thinking of buying a forklift battery, it can be helpful to know a little bit more about how they’re designed. With that goal in mind, here’s a brief guide to the anatomy of a lead acid forklift battery. (For more detailed information, see the Battery Intelligence section of our website.)

The first thing to understand about a forklift battery is that it isn’t just for powering your forklift. These batteries are heavy, so they also provide extra weight, which makes it easier for the forklift to pick up heavy objects by acting as a counterweight.

The next thing to understand is that it’s important to follow all safety procedures strictly. Serious accidents can occur if safety standards aren’t followed.

Parts of a Battery

A typical lead acid battery is made up of four basic parts: the case, the cells, the inter-cell connectors, and the cables.

The case is what holds all the cells together, so it’s basically a big box.

The cells are a group of between six and 40 individual batteries, each made up of lead plates and sulfuric acid, packed tightly together in the case.

The inter-cell connectors are also made of lead, and their purpose is to link the individual cells to each other so the battery will form a complete circuit.

The cables vary in size depending on the amperage, with higher amps requiring thicker cable.

Along with these four basic components there can also be a water monitor, which will display a green light when the battery has enough water and a red light when it needs more.

If you need to replace your current forklift battery, just sell it to us here at Green Power Forklift Batteries! Green Power can also sell you new or reconditioned forklift batteries. Keep your forklifts running and help the environment at the same time, by getting as much life as possible from your forklift batteries!

Keep Your Forklift Battery Alive Longer

Refurbished Forklift Batteries

Lead-acid forklift batteries are the most popular type of forklift battery for several reasons. The first and most obvious reason is that they’re the least expensive option available, but on top of that they’re also reliable, tough, recyclable, and safe when handled properly.

The typical lifespan of a lead-acid forklift battery is 1,500 charge cycles, which adds up to about five years. After yours has reached the end of its lifespan, you can always sell it to Greenpower Forklift Batteries to be refurbished, but you can make it last as long as possible by following these simple tips.

1: Washing

Your forklift battery needs to be washed with water and battery acid neutralizer to clean off the corrosive buildup that would otherwise damage your terminals and casing, shortening the lifespan of your forklift battery over time. Make sure to observe all OSHA and EPA regulations while washing. Don’t charge it again until it’s completely dry.

2: Watering

You should check the water level on your forklift battery after every five charges, adding clean water on an as-needed basis. Fill the water no more than ¼” above the plates. Be careful not to under-water or over-water and add water only after fully charging.

3: Equalizing

Battery equalization procedures vary from one manufacturer to another, so make sure to follow the instructions specific to your manufacturer. Equalization needs to be performed after every 5-10 charges and should be a regularly scheduled part of your battery maintenance plan.

If you follow these tips, your forklift battery should last much longer than it otherwise would. When you do need to replace it, you can always sell it to Greenpower Forklift Batteries and buy a new or refurbished forklift battery to replace it. By refurbishing older batteries so they last as long as possible, Greenpower Forklift Batteries is doing our part to help the environment!

A Brief Guide to Forklift Batteries

Refurbished Forklift Batteries

The unique 18-stage renovation process we use at Greenpower Forklift Batteries allows us to extend the lifespan of industrial lead acid batteries, but there are also other types of forklift battery in existence including AGM and Lithium-Ion varieties. This brief guide to forklift batteries will teach you all about the different types.


“AGM” stands for “Absorbed Glass Mat,” so called because this type of battery uses a fine glass mat to store electrolytes in a “dry” condition. AGM forklift batteries are a special type of lead acid battery. They require less maintenance because they don’t need to be watered, and they also don’t have the risk of spilling battery acid. The main disadvantage of an AGM battery is that overcharging can reduce their lifespan, and they are also more expensive than other types of lead acid batteries. Green Power Batteries does not currently carry AGM batteries.


Lithium-ion forklift batteries are becoming more common, despite the fact that they are a more expensive option. They offer a number of advantages, including the fact that they don’t need watering or maintenance and there’s no risk of overcharging them. They can be charged quickly and are safer for workers to handle. On the other hand, they are expensive enough that some businesses cannot afford to use them. In addition, they should not be stored when fully charged and they should not be stored in high temperatures or they can be damaged as a result.

Lead Acid Forklift Batteries

This is the most common type of forklift battery. They are also known as “wet cell” batteries because they use a combination of sulfuric acid and water. They need regular maintenance to perform well over time, and they need regular watering to keep electrolytes at the correct level. The big advantage of lead acid batteries is that they’re more affordable, but they do need to be maintained properly to last their full lifespan of five years or more.

If your lead acid forklift batteries are no longer working for you, why not sell them to Greenpower Forklift Batteries? We’ll put them through our refurbishing process and extend or even double their lifespan! Greenpower Forklift Batteries can also sell you new or reconditioned forklift batteries. Keep your forklifts running in the most environmentally friendly way possible by getting all the life you can from your forklift batteries!