As more of our industry migrates towards electric forklifts, it is important to maintain your forklift batteries and chargers. Properly maintained forklift batteries and chargers will:
Perform better on a daily basis by holding charges longer and maximizing output
Last longer! By maintaining your batteries and chargers to manufacturer's recommendations, you ensure the longest life possible
Be safer to work around. Poorly maintained batteries and chargers can present a danger to those working near or on them
This month we provide some tips to help you get the most out of your forklift's batteries and chargers.
Battery Maintenance Tips
Charge Properly
Only charge when the battery is between 20–30% capacity (don’t top off during shifts).
Always allow a full charge cycle—avoid interrupting mid-charge unless absolutely necessary.
Maintain Proper Water Levels
Check electrolyte levelsweekly, and top off with distilled waterafter charging if needed.
Never overfill; it can cause overflow during charging.
Keep Batteries Clean
Regularly clean the battery case and terminals with a damp cloth or baking soda solution (neutralizes acid residue).
Corrosion or dirt buildup can lead to energy loss or safety hazards.
Equalize Charges
Perform an equalization charge (a longer charge to balance cell voltage) weekly or per manufacturer’s recommendation to prevent sulfation and extend life.
Inspect for Damage
Look for cracks, bulges, corrosion, or leaks.
Tag and remove damaged batteries from service immediately.
Monitor Temperature
Keep batteries in a cool, dry place. Overheating during charging can reduce battery lifespan.
Avoid exposing batteries to extreme temperatures (ideal range: 60–80°F).
Charger Maintenance Tips
Use the Correct Charger
Always use the manufacturer-recommended charger for the specific battery type and voltage.
Inspect Cables & Connectors
Check for frayed wires, loose connections, or melted plugs regularly.
Damaged connectors can cause poor charging or fire hazards.
Keep Chargers Clean & Ventilated
Ensure chargers are free of dust and debris and have proper airflow to avoid overheating.
Don’t “Opportunity Charge”
Charging during short breaks or lunch can shorten battery life unless the battery is designed for it (like lithium-ion models).
Log Charging Activity
Keep a charging log or use battery management software to track usage and detect early signs of trouble
Bonus Tip:
Training operators and technicians on proper battery handling and safety procedures is key to avoiding damage and extending battery and charger life.
Maintaining forklift tires properly can extend their life, improve safety, and enhance operator comfort. Here are some practical tips for keeping your forklift tires in good condition:
Perform Regular Inspections
Check for wear and damage: Look for cracks, chunking, flat spots, or excessive wear. Make tire inspections part of your normal forklift pre-shift inspection, as required by OSHA. Download our Forklift Inspection Forms HERE.
Inspect tread depth: On pneumatic tires, ensure there’s enough tread for traction and cushioning.
Look for signs of separation or embedded debris.
Maintain Proper Tire Pressure (Pneumatic Tires)
Check inflation daily: Under- or over-inflated tires can cause uneven wear and reduce stability.
Use manufacturer-recommended pressure settings.
Rotate Tires
Even out wear patterns by rotating tires regularly (especially on multi-wheel forklifts).
Avoid Overloading
Stick to the forklift’s rated capacity. Excess weight increases tire wear and risk of failure.
Drive Smart
Avoid sharp turns, quick starts/stops, and high speeds.
Reduce impact with curbs, potholes, or dock edges to prevent tire damage.
Maintain Clean Work Areas
Debris, sharp objects, and uneven surfaces can puncture or wear tires prematurely.
Sweep aisles regularly and repair uneven flooring.
Replace Worn Tires Promptly
Cushion tires: Replace when wear line is reached or when the tire diameter is 2 inches less than original.
Pneumatic tires: Replace when tread is worn down or casing is damaged.
Use the Right Tire for the Application
Cushion vs. pneumatic: Make sure your forklift has the correct tire type for your environment (indoor vs. outdoor).
Consider solid pneumatics for heavy-duty or debris-laden areas to avoid flats.
Selecting the proper tires for your forklift and maintaining them is key to creating a safe working environment for your employees, and keeping your costs down by getting the most out of each set of tires you purchase. For more information about forklift tire replacement visit our Forklift Tire Replacement page, or contact us at 804-233-0051 for information and pricing. We replace tires for ALL MAKES and MODELS.
As summer temperatures rise, so do the risks for heat-related illnesses—especially for workers in the material handling and warehouse industries, where physical exertion and limited airflow are part of the daily routine. Whether employees are loading trucks outdoors, managing logistics in open-air yards, or working in non-climate-controlled warehouses, staying cool isn’t just a matter of comfort—it’s a matter of safety. Employers have a responsibility to protect their teams from heat stress and related hazards. This article offers practical, proven tips to help keep your workforce safe, cool, and productive throughout the hottest months of the year.
1. Hydration Strategies
Water stations: Place multiple shaded water stations with coolers or dispensers filled with ice water.
Electrolyte options: Offer sports drinks or electrolyte powders to replenish salts lost through sweat.
Hydration reminders: Use signs, mobile app reminders, or supervisors to prompt workers to drink water every 15–20 minutes.
2. Shade & Rest Breaks
Pop-up tents or canopies: Provide shaded areas at regular intervals.
Portable misting tents or fans: Use cooling fans or misting systems in rest areas.
Mandatory cool-down breaks: Schedule 5–10 minute breaks in the shade every hour, more frequently if temps are above 90°F.
3. Clothing & Gear
Lightweight, breathable fabrics: Encourage moisture-wicking clothing in light colors.
Cooling gear:
Cooling vests (ice-pack or evaporative)
Neck wraps or towels soaked in cold water
Wide-brimmed hats or brim extensions on helmets for sun protection
UV-protective gear to prevent sunburn and overheating.
4. Work Schedule Adjustments
Start earlier or split shifts: Begin work at sunrise and pause during peak heat hours (typically 12–4 p.m.).
Rotate tasks: Alternate between physically intense and less demanding tasks.
Use buddy systems to monitor for signs of heat illness.
5. Cooling Equipment
Battery-operated fans: Personal wearable fans for hard-to-reach sites.
Portable misting fans: For job trailers or staging areas.
Ice chest/coolers: Keep cold towels or drinks handy.
6. Training & Awareness
Heat illness prevention training:
Teach symptoms of heat exhaustion and heat stroke.
Emphasize the importance of acclimatization.
Post safety signs in common areas with visual cues for heat illness symptoms and first aid steps.
7. Technology Solutions
Wearable sensors: Monitor core body temp or heart rate (ideal for high-risk environments).
Weather alert apps: Notify crews when heat advisories are issued.
8. Environmental Enhancements
Temporary shade structures near worksites.
Pavement wetting (for road crews) to reduce ambient surface temperature.
Tree planting (long-term) or use of artificial vertical shade barriers where possible.
