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620 OSHA Forklift Certification | OSHAcademy Online Training
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Battery Charging and Changing Procedures

An electric forklift is designed to operate for one shift and then be charged on the next shift or overnight.

The battery is hoisted from forklift compartment with lifting beam.

Some employers routinely change batteries instead of charging them in the vehicle. The discharged battery is removed from the forklift and a charged battery is installed in its place.

Batteries are heavy and contain sulfuric acid that is highly corrosive and could be splashed on personnel servicing or changing batteries. Toward the end of the battery charging process, batteries can give off highly explosive hydrogen gas. Contact with battery cells can cause electrical short circuits, which can burn unprotected skin.

Only trained personnel should charge and change batteries in electric forklifts. In addition to training in battery changing and charging procedures, these employees should be trained on emergency procedures in the event of an acid splash, including how to use eyewash and shower facilities.

Always follow your facility's specific safety procedures.

  • When charging batteries, pour acid into water. Never pour water into acid.
  • Check to assure that vent caps are functioning properly. The battery (or compartment) cover(s) should be open to dissipate heat.
  • Prohibit smoking in the charging area.
  • Take precautions to prevent open flames, sparks, or electric arcs in battery charging areas.
  • Remove all metallic jewelry before recharging. Tools and other metallic objects must be kept away from the top of uncovered batteries.
  • Wear personal protective equipment (face shield, safety goggles, neoprene or rubber gloves and apron).
eye wash station.
Suitable facilities for quick drenching or flushing of the eyes and body must be provided within the work area for immediate emergency use.
  • Where the eyes or body of any person may be exposed to injurious corrosive materials, suitable facilities for quick drenching or flushing of the eyes and body must be provided within the work area for immediate emergency use.
  • Check the electrolyte level before recharging. Record the specific gravity with the hydrometer in the service log. Check the pilot cell.
  • Check the water level. Do not add water prior to recharging. Record in service log.
  • Check the voltage. If the battery has sealed vents, do not recharge with a current greater than 25 amperes.
  • Unplug and turn off the charger before connecting or disconnecting the clamp connections.
  • Attach the positive clamp (+, usually colored red) to the positive terminal first and then the negative clamp (-, usually colored black) to the negative terminal, keeping the proper polarity.
  • Turn off the charger if the battery becomes hot or the electrolyte fluid comes out of the vents. Restart charging at a lower charging rate.
  • Check water level after charging. Add distilled water or de-ionized water if water level is below level indicator. Record in service log.
  • Return battery to forklift with lifting beam and secure in place after charging.
  • Check the indicator on the hour meter to see that battery is fully charged.

Knowledge Check Choose the best answer for the question.

4-6. Batteries are heavy and contain _____ and could be splashed on personnel servicing or changing batteries.