Lead-Acid Battery Charging SOP

Purpose:

• Provide practical guidance for protecting workers from injury while charging lead-acid batteries.

Equipment required:

• PPE: face shield, acid-resistant gloves, long pants, closed-toed shoes (water level check & refill).
• Forklift battery & charging equipment.
• Battery spill kit, specific to the type of battery being charged.

Hazards:

• electric shock, fires & explosions, hydrogen gas, contact with reactive chemicals.

Important considerations:

• Use weak bases like baking soda to neutralize acids. Strong bases with strong acids can cause violent chemical reactions. Mix weak base into acid well, before wiping up a spill.
• Overfull batteries can cause acid to bubble up and create hydrogen gas while charging and filling.
• Vehicle use affects battery life. Follow the maintenance schedule and all other necessary recommendations as specified by the manufacturer.
• Locate and consult forklift operator’s manual or Battery SDS for additional precautions not mentioned.

Set up charging area:

1. Locate and consult forklift operator’s manual to find type of charger, charging device settings, and other specifications.
2. Have all necessary charging equipment located in a designated charging area:
   1. Locate charging equipment to somewhere cool, well-ventilated, and level (if parking forklift there).
      1. Mechanical ventilation may be needed to bring gas concentrations in work areas to safe levels. Make sure intake brings in only clean air and exhaust is away from sources of ignition.
   2. The work area must be made clear of fire hazards. Smoking or open flames are prohibited within charging areas.

Before plugging in:

3. Park and turn off the forklift, remove and hold onto key to prevent ignition, disconnect the battery from vehicle and charging equipment. Inspect for any damage to the battery.
   1. 
4. Follow UW-Madison Lead-Acid Battery Refill SOP to check, and if needed, refill water levels. Not applicable to Nickel-Cadmium Batteries or Lithium-Ion Batteries.
   1. This can be done weekly or more frequently, depending on the level of use.
   2. 
5. Make sure the charger is not plugged into a power source to prevent shock.

Plugging in battery:

6. Connect positive cable clamp/connector (+) to positive terminal. Positive cable is colored red.
7. Connect negative cable clamp/connector (-) to negative terminal. Negative cable is colored black.
8. Plug in charger into grounded GFCI-protected outlet. Plug directly into outlet, don’t use an adapter.
9. Verify that charging device is set to or set device to the manufacturer’s recommended settings for battery.
10. Monitor battery charge levels periodically. Pull on the charging device’s plug to disconnect charger from power to remove batteries that have completed charging. Do not pull on cord, as this can damage the plug.