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.

Should You Opportunity Charge Your Forklift Battery?

Should You Opportunity Charge Your Forklift Battery?

Opportunity charging charges forklift batteries in a fraction of the time conventional charging takes, but this method isn’t the best option for every business. Continue reading to learn if you should opportunity charge your forklift battery.

How Opportunity Charging Works

Opportunity charging is when a forklift operator charges their lift truck’s battery during a short downtime, such as during lunch, rest breaks, or shift changes. At the end of the charge period, the battery has enough power to last until the next charge.

Opportunity charging takes 10 to 30 minutes, and batteries need a weekly equalization charge to 100 percent. Typical opportunity chargers will charge the battery up to 80 percent before shutting off.

Benefits for Two-Shift Operations

If your facility operates two shifts, you should consider opportunity charging forklift batteries. This charging method gives the battery enough power to work through both shifts, boosting productivity. And because the batteries spend more time powering lift trucks, opportunity charging can let you do the same amount of work with fewer batteries.

Conventional charging typically requires 8 hours of continuous charging, followed by a cooldown period. Opportunity charges save time by taking advantage of natural breaks in the work schedule. It also saves time by minimizing how often operators change out the batteries.

Limitations of Opportunity Charging

Opportunity charges work best for facilities that run two-shift operations. With only one shift per day, conventional charging is convenient. Conventionally charged batteries also have a longer working lifespan than opportunity-charged batteries.

Facilities that use three shifts can benefit best from fast charging. Compared to opportunity charging, fast charging cycles take less time and charge the battery to a lower state of charge. But of the three charging methods, fast charging will decrease the battery’s overall lifespan the most.

If you decide to use opportunity charging, strategically place the chargers near break rooms and work areas. This makes it more efficient for staff to charge their lift truck batteries during breaks.

Green Power Forklift Batteries has new and refurbished forklift batteries for sale. Whether you run forklifts on single or multiple shifts, our lead-acid batteries will power your equipment reliably. Shop with us today for high-quality forklift batteries.

The Safest Ways To Move a Forklift With a Dead Battery

The Safest Ways To Move a Forklift With a Dead Battery

When your lift truck’s lead-acid battery dies, you need to move the forklift to the charging station so you can extract and charge the battery. Read on to discover the safest ways to move a forklift with a dead battery.

Swap Batteries

If your lift truck has a side-loading compartment rather than a top-loading compartment, you could potentially swap batteries without moving the dead lift truck. You’ll need a charged backup battery and a mobile battery extractor. The mobile battery extractor enables you to change out the battery anywhere in your facility.

Follow the battery extractor manufacturer’s instructions to pull the battery out safely. Features like friction strips and rollers on the battery changer will let the machine move the battery into the device’s compartment and keep it secure during transport.

Tow It In

One of the safest ways to move a forklift with a dead battery is to tow it using your equipment manufacturer’s instructions found in the service manual. The towing forklift must have enough braking capacity, weight, and power to control both trucks for the grade and distance. You may need to connect additional lift trucks to the rear of the disabled lift truck to prevent uncontrolled rolling if moving downhill.

Consult your service manual for instructions for your specific model. The towing lift truck will need a shield to protect the operator if the tow line breaks. Keep the tow line angle to a minimum and connect the tow line as low as possible to the disabled lift truck.

The disabled truck’s service brake pedal should be released, the key switch in the off position, and the direction control lever in neutral. Travel over a short distance and move slowly, at about 1 mph.

Jump-Start the Dead Battery

Another option for moving the disabled forklift is to jump-start the dead battery. The live battery should have the same voltage as the dead one. Follow your manufacturer’s instructions so you don’t damage your forklift’s electrical system or cause injury.

Check the fluid levels before starting. Move the operational truck close enough for the cables to reach the dead battery. Turn off both forklifts and engage each truck’s parking brake.

Attach the red jumper cables to the positive terminals of the live and dead batteries. Attach one end of the black cable to the functioning battery and the other to a piece of solid, stationary metal on the dead forklift’s engine, at least 18 inches away.

Start the engine of the functioning lift truck and let it idle for several minutes. Next, start the disabled forklift and let it run for a few minutes.

Remove the cable attached to the metal first, then the black cable connected to the negative terminal. Finally, remove both of the red cables.

Practice proper charging to maximize the lifetime usage of your batteries. Once you need a replacement, visit Green Power Forklift Batteries. We offer a range of options for industrial forklifts, including Crown forklift batteries. Shop with us today for a new battery.

Saving Money And The World With Recycled Forklift Batteries

Refurbished Forklift Batteries

It’s that time of year again and you need to buy batteries for your forklifts, but your yearly budget is looming. Surely there must be an alternative, a more affordable way to run your forklifts.

Perhaps it’s time you considered the option of buying recycled forklift batteries. You may be thinking that a recycled forklift battery could never do the job of a brand new battery straight off the production line, but with GreenPower batteries you will be buying a product that not only does the same job as a brand new battery but will help to lighten the load on your budget.

GreenPower batteries has a wide range of recycled forklift batteries that are put through a rigorous 18 stage reconditioning process  that ensures that when you buy your recycled forklift batteries from us, you are buying a high quality functional product.

Still not convinced? what if I told you that buying our recycled forklift batteries can help to lower your carbon footprint and ensure your company can do its part to help preserve the environment. So not only are you saving money with GreenPower batteries you are also saving the environment for future customers.

We have an extensive list of recycled forklift batteries available so why not peruse our list below and remember that the only differences between a new forklift battery and a recycled forklift battery is cost and making the world a better place.

Green Power Batteries buys,sells and ships used or scrap forklift batteries throughout the USA and Canada.

Your Name

Company Name

Zip Code (Ship To)


Phone (optional)

Message: How can we help you?

Recycled Forklift Batteries

Refurbished Forklift Batteries

So your Forklift has been sluggish lately and unresponsive. Perhaps it’s time to fork out some money for a brand new battery and get your business back on track. But wait, what if their were a cheaper option available that could not only save your company money but also help to reduce your carbon footprint.

Green power batteries offer an amazing range of recycled forklift batteries at an affordable price and when you buy a recycled forklift battery from us you know you will be purchasing a high quality product. All of our recycled forklift batteries go through a rigorous 18 stage reconditioning process which means that when you buy from us, you buy the best recycled forklift batteries.

Recycled forklift batteries are not only more affordable, they are a great way to show that your company is doing its part to help the environment while retaining a high level of output from your forklifts. You can be safe in the knowledge that you are buying the best recycled forklift batteries when you buy from Green power batteries. Just take a look at our qoutes at the bottom of the page.

There are recycled forklift batteries to suit all kinds of forklifts and if you want to purchase a brand new battery, we stock those as well.

Green Power Batteries buys,sells and ships used or scrap forklift batteries throughout the USA and Canada.

Your Name

Company Name

Zip Code (Ship To)


Phone (optional)

Message: How can we help you?