Why inspecting electric truck batteries is crucial

When carrying out a Thorough Examination of electric lifting equipment, checking the safety of the battery is a vital part. From electric counterbalance forklifts to reach trucks and powered pallet trucks, the battery is the power source and as such needs to be in safe working order.

Electric trucks have become increasingly popular in recent years due to their efficiency and eco-friendliness. However, with this new technology comes new safety concerns. One of the most important aspects of maintaining a safe electric truck is inspecting the battery. In this article, we will discuss why inspecting the battery on electric trucks is so important and what steps should be taken to ensure its safety.

The Importance of Battery Safety

The battery is the power source for electric trucks, making it a crucial component of the vehicle. It is responsible for providing the necessary energy to operate the truck, and any malfunction or damage to the battery can have serious consequences. This is why it is essential to regularly inspect the battery to ensure it is in safe working order.

Explosive Gases and Ventilation

One of the main reasons why inspecting the battery is so important is due to the presence of explosive gases. When the battery is being charged, it produces hydrogen gas, which is highly flammable. Therefore, it is crucial to have proper ventilation in the charging area to prevent any potential explosions. Keeping the battery in a cool environment can also help reduce the risk of overheating and potential explosions.

Water Levels and Battery Life

During an inspection, the water levels in the battery will also be checked. Low water levels can cause the battery to overheat, resulting in the production of more explosive gases. It is essential to keep the battery cool during charging and maintain the correct water levels to prolong its lifespan. With proper maintenance, a 48v battery can provide up to 5 hours of power, but this can decrease significantly if the water levels are not maintained.

Corrosion and Insulation

Another crucial aspect of battery safety is ensuring that the battery cables and terminals are free of corrosion and 100% insulated. Corrosion can cause the battery to short to the chassis or the positive and negative terminals, resulting in sparks and, in extreme cases, fires. It is also important to have a battery plug handle present to prevent the operator from pulling on the cables when unplugging the battery from the truck.

Battery Container Inspection

Aside from checking the battery itself, it is also essential to inspect the battery container in which it is fitted. Battery acid can leak and corrode the container, causing the battery to fall through the bottom of the box. This can be extremely dangerous and can result in serious accidents.

Dust and Debris Prevention

Lastly, keeping the top of the battery free from dust and debris is crucial to prevent the cross-tracking of voltage between cells. This can affect the battery’s running time and lifespan, especially when the battery is overfilled, and the dust turns into mud.


In conclusion, inspecting the battery on electric trucks is a vital part of maintaining a safe and efficient vehicle. It is essential to regularly check the battery’s water levels, ensure proper ventilation, and keep the battery and its container clean and free from corrosion. By following these steps, you can prolong the battery’s lifespan and prevent any potential accidents. Remember to always conduct a pre-use daily inspection and refer to a checklist for guidance. Stay safe and keep your electric truck running smoothly

A 48v battery can cost around £4,000 and individual cells around £300, so ensuring your battery is safe, clean and well looked after should be part of your pre-use daily inspection. You can find a checklist on what to look out for here.

Clean battery in electric forklift

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