Greenworks Tools has recalled 554,780 Kobalt-branded power tool batteries over fire and explosion risks tied to USB-C charging. The company received 34 reports of batteries producing smoke, sparking, or igniting while inserted in tools during charging.
The affected batteries are lithium-ion units designed for Kobalt's cordless yard work tools. Greenworks identified a defect in the battery's charging circuit that causes thermal runaway, where the cell temperature rises uncontrollably. This condition creates immediate hazard zones around the tool during charging.
The recall spans multiple battery models sold at Home Depot and other retailers between 2021 and 2024. Greenworks confirmed one minor burn injury related to the defect. The company notes that while incidents remain rare relative to units sold, the severity of potential harm justifies the broad recall action.
Consumers can receive either a full refund or replacement batteries that address the charging circuit flaw. Greenworks recommends customers stop using affected batteries immediately and unplug charging cables if smoke or sparks appear.
This incident reflects broader quality control challenges in consumer lithium-ion battery manufacturing. USB-C has become standard for power tool charging due to its convenience and fast-charge capability, but thermal management during charging remains technically demanding. Defects in charge controller firmware or hardware can trigger the kind of failure Greenworks documented.
The recall positions Greenworks differently than competitors. DeWalt, Milwaukee, and Makita have maintained proprietary charging systems longer, accepting slower charge times in exchange for stricter quality control. Greenworks' decision to adopt USB-C earlier provided competitive advantage but exposed it to supply chain risks if manufacturing partners cut corners.
Affected battery models include specific Kobalt SKUs sold primarily through Home Depot. Greenworks has set up a dedicated recall hotline and online portal for returns. The