How to Charge a Forklift Battery

Electric forklifts are becoming increasingly popular due to their countless advantages and environmental factors. There are two types of electric forklifts, the new lithium powered technology and the traditional lead acid forklifts. Both battery types need to be charged in a specific way to get the best use out of them, so following a set charging procedure is advised to help you keep on top of your battery’s health.  

Below, we will outline the best charging procedures and steps to correctly charge your forklift battery, helping you maintain your batteries health and get the most out of its lifespan. 

Steps to Charging a Lead Acid Battery:  

You can either charge lead acid batteries directly from the forklift, or if the forklift is working a double shift, you can remove and replace them. Handling lead acid batteries can be dangerous, putting you at risk of burns from the battery acid and exposure to toxic fumes. You should have completed training and follow a proper procedure to ensure safety of yourself and the battery.  

1 - Park the Forklift 

You must make sure your forklift is properly parked and turned off, ensuring the parking brake in on. Once parked, raise the seat so you have access to the forklift battery underneath. Every site that uses an electric forklift should have a safe charging station. Your dedicated forklift charging area requires several safety features, such as: 

• Adequate ventilation 
• Fire extinguisher 
• Eyewash station 
• No smoking signs 
• Acid neutralisation materials 

2 - Put on Your PPE 

Make sure you are wearing appropriate PPE, such as face shields, safety glasses, gloves and an apron. This will help to protect you against acid splashes or burns from the lead acid battery. Remove any metal jewellery to lower the risk of electrocution.  

3 - Find the Correct Charging Cable  

Select a charger that matches the output voltage and amp hours (ah) capacity of the forklift battery - you will find this information on the data tag.  

4 - Check the Cables for Damage  

Ensure the charging cables are in good condition with no signs or burning, damage or cracks. If you find any damage or loose cables to the battery, do not proceed and get this repaired before using.  

5 - Disconnect the Battery Cable  

Disconnect the battery cable from the forklift. If you need to remove the battery from the forklift, do not lift it manually and use a pallet truck or forklift - make sure it is secure before transporting.  

6 - Connect the Charging Cable  

Connect the charger to the battery. Ensure you do not plug the charger into the forklift terminal as this could damage both the forklift and charger. Do not charge the forklift battery if it is too hot or too cold. Check to ensure the battery indicates that its charging is in progress.  

7 - Charge the Battery  

To get the most out of your charge, follow the ‘8-8-8’ rule, also known as the conventional charging method.  

• 8 hours in operation
• 8 hours charging
• 8 hours to cool down 

8 - Take it off Charge  

Once the charge is complete, you need to take it off charge. Ensure that you always turn off the charger before unplugging the charging cable. Plug the battery cable back into the forklift.  

9 - Check the Water Levels  

When the battery has charged and cooled down, you can check the water levels by removing the caps. Add the appropriate amount of water to each cell - ensuring you don't over or underwater the battery. Top tip: Use a single point watering system to save time. To prevent damage, don’t water the battery before charging and make sure you keep a log of every time you water the battery.  

10 - Maintain the Battery  

Looking after your battery and ensuring proper maintenance helps to extend the lifespan of your battery, allowing you to get the most out of it. To avoid damaging the battery, you should charge it once it reaches around 20-30 percent and do not let it run down to 0 percent.

Charging a forklift battery between 20% and 30% provides the ideal balance of battery life, performance and downtime. Visit 5 tips for forklift battery maintenance for more tips and tricks on how to upkeep your battery.  

 

Steps to Charging a Lithium-ion Battery:  

Charging lithium-ion forklifts is a simple and easy process, due to the safety and zero maintenance of the new technology. You do not require a dedicated safe charging area, or any PPE in order to charge a lithium battery. Follow the simple steps below to charge your battery. 

1 - Park the Forklift  

Park the forklift properly, use the parking brake, turn off the ignition and remove they key. Ensure you are parked near a power outlet. 

2 - Find the Correct Charging Cable 

Ensure the charger is compatible with the forklift battery and is in good working condition. 

3 - Connect the Charger to the Power Supply  

Plug the charger into the power outlet. Ensure the power supply matches the voltage and current requirements.  

4 - Connect the Charger to the Battery  

Open up the charging port and plug the charger into the battery’s port.  

5 - Check it is Charging 

Ensure there is a secure and proper connection, and make sure the charger is functioning correctly. 

6 - Charge the Battery  

A full charge takes around 2 hours, however lithium batteries can be opportunity charged in 15–30-minute top up’s, meaning they can be charged during breaks and any downtime when the forklift is idle for a few minutes.  

7 - Take it off Charge  

Once you have finished your full charge, or topping up the battery, turn off the charger and remove it from the battery's charging point. Lithium batteries do not require a cooling-off period like lead-acid batteries, so you can use them straight away.  

8 - Maintenance Tips  

The lithium batteries run best and have a longer life span when kept at high charge, so if the truck is not in use for longer than 15 minutes, plug it in. You only need to fully charge a lithium truck every once in a while, so they are great for frequent and fast charging without the risk of overheating.  

Looking For a Forklift Battery?

Properly charging forklift batteries, whether lead-acid or lithium-ion, is crucial for maximising their lifespan and ensuring safe operation. By following the outlined steps for each battery type, you can maintain optimal performance and efficiency for your forklift. If you need a new battery or charger, or require any further information about your forklift, contact PHL today.