10 Essential Battery Maintenance Checks That Keep Your Operation Moving

When it comes to running a busy warehouse or logistics operation, your lead-acid batteries are the unsung heroes. They power your trucks, your lifts, your fleet, but only if they’re properly looked after.

Neglect a battery, and you’ll soon notice the difference: more downtime, shorter run-times, and in some cases, expensive replacements that could have been avoided.

Here are 10 simple checks every technician (or operator) should keep on their radar and why they make all the difference.

1. Give it a once-over

A quick visual inspection can spot the obvious problems before they become costly ones. Cracks, bulges, or corrosion on trays are red flags that shouldn’t be ignored.

2. Check electrolyte levels

Electrolyte keeps your plates healthy. Too low, and you risk sulfation (which can’t be reversed). Too high, and you’ll be mopping up acid. If you’ve got a filling system, double-check that the floats and tubing are working properly.

3. Trust, but verify sensors

Electrolyte sensors are brilliant for saving time, but only if they’re working. A loose or faulty sensor can give you misleading information, so it’s worth making sure they’re secure and accurate.

4. Test the state of charge

A quick hydrometer check or monitoring system reading tells you the real story of your battery’s health. If cells aren’t lining up, it’s an early warning that something’s not right.

5. Watch the volts

Recording cell voltages is like a health check for your battery. Spotting weak cells early means you can fix the problem before it spreads. And don’t skip equalisation charges,  they keep the whole battery balanced.

6. Inspect the cables

Take-off leads and cables take a lot of strain. Loose or damaged ones cause heat build-up and wasted energy — not to mention potential safety hazards. Tight, clean connections are key.

7. Tighten up intercell connectors

Connectors are the bridges between cells. If they’re loose or corroded, you’ll lose efficiency and build up heat. A quick torque check keeps them doing their job.

8. Keep vents clear

Vent caps do an essential job: letting gases escape safely. If they’re clogged or damaged, pressure can build up where you don’t want it. Clean vents and working flame arrestors are a must.

9. Don’t forget the clean-up

Dust and acid residue on the top of a battery might look harmless, but it can slowly discharge your battery even when it’s not in use. A clean battery is a happy battery.

10. Record everything

Maintenance logs aren’t just paperwork; they’re a record of your battery’s history. Track your checks, keep safety labels clear, and you’ll spot patterns that help you prevent bigger problems down the line.

✅ The bottom line: A little time spent on these 10 checks can mean longer battery life, fewer breakdowns, and safer operations. For a fleet that keeps your business moving, that’s time very well spent.

We've put together a handy checklist for you to follow next time you're doing your essential battery maintenance. Click here to download it.