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.