Forklift Battery Charging & Change-out Safety Checklist

Is the battery charging area equipped with adequate ventilation to prevent hydrogen gas accumulation (e.g., mechanical exhaust system)?

Is a hydrogen gas detector present and calibrated to alarm at or below 1% (25% LEL) hydrogen concentration?

Is an eyewash station located within 10 seconds (or 100 feet) of the battery charging area, on the same level, with unobstructed access?

Is the eyewash station flushing freely with potable water for a minimum of 15 minutes, and is the water tepid (60-100°F)?

Is an acid spill kit readily available and fully stocked with neutralizing agents, PPE, and disposal bags?

Are 'No Smoking' signs clearly posted within 50 feet of the battery charging area?

Is a Class C fire extinguisher (suitable for electrical fires) readily accessible and fully charged?

Is the floor in the battery charging area acid-resistant and free from cracks or damage that could trap spilled acid?

Is there adequate lighting (minimum 50 foot-candles) in the battery charging area to safely perform tasks?

Are spare batteries stored on designated racks or pallets, preventing direct contact with the floor?

Are acid-resistant aprons available and in good condition for all personnel handling batteries?

Are acid-resistant gloves (nitrile or neoprene) available and in good condition for all personnel handling batteries?

Are full-face shields or safety glasses with side shields available and in good condition for all personnel handling batteries?

Is PPE inspected before each use for tears, punctures, or other damage?

Have all personnel been trained on the proper use, maintenance, and disposal of PPE?

Are safety shoes with steel toe protection worn by all personnel handling batteries?

Is there a written eye protection policy enforced in the battery charging area?

Is there a designated area for storing PPE when not in use, away from potential contamination?

Are procedures in place for cleaning and decontaminating PPE after each use?

Is the battery extractor (if used) in good working order, with all safety features functioning correctly?

Is the battery extractor rated for the weight of the batteries being handled?

Is the battery extractor inspected daily for damage, wear, or missing parts?

If a hoist is used, is the chain or strap inspected for wear, damage, or deformation before each use?

If a hoist is used, is it rated for the weight of the batteries being handled, with a clear load rating visible?

If a pallet jack is used, are the wheels and lifting mechanism in good working order?

Are lifting slings (if used) inspected for cuts, abrasions, or chemical damage before each use?

Have all personnel been trained on the safe operation of the battery handling equipment?

Is there a documented maintenance schedule for the battery handling equipment?

Is the battery charger voltage compatible with the battery being charged?

Is the battery charger free from damage, with all cables and connectors in good condition?

Are all battery cables and connectors properly insulated and free from exposed wires?

Are all battery vent caps in place and functioning correctly?

Is the area around the battery charger clear of obstructions and flammable materials?

Are battery connections clean and tight, preventing arcing or sparking?

Is the battery charging process monitored to prevent overcharging or overheating?

Is the electrolyte level in the battery checked regularly and maintained at the proper level with distilled water?

Is the battery temperature monitored during charging to prevent overheating?

Are the charger's operating instructions readily available and followed?