Your operation runs on its forklifts, and your forklifts run on their batteries. Whether you’re evaluating a new purchase, sizing a replacement or trying to get more life out of your current fleet, you may have questions about forklift battery selection and the most appropriate preventive maintenance practices.
What Types of Forklift Batteries Are There?
The two main battery types that power today’s electric forklifts are lead-acid and lithium-ion. Lead-acid batteries have been the warehouse standard for decades, built around a flooded cell design that has reliably powered forklifts across a wide range of applications. They operate on an eight-hour charge cycle followed by an eight-hour cooldown period, making them a natural fit for single-shift operations.
An electric forklift battery using lithium-ion technology features a sealed-cell design and reaches full charge in one to two hours, with no cooldown required. Lithium-ion also supports opportunity charging — short top-off charges during breaks or between shifts — making it the stronger choice for multishift and high-throughput environments.
How Much Does a Forklift Battery Cost?
The cost of a forklift battery varies by type, voltage and capacity. Lead-acid batteries cost less, but ongoing maintenance adds to the total cost over time. Lithium-ion batteries require a larger initial investment but deliver a lower total cost of ownership through a longer lifespan and fewer maintenance demands. If a lead-acid battery is losing capacity, reconditioning may restore performance and delay the need for replacement.
What Size Forklift Battery Do I Need?
Battery size is determined by your forklift’s voltage requirement and battery compartment dimensions. Before purchasing, check your forklift’s data plate, also called the capacity plate, which lists the required voltage and amp-hour (AH) rating. Common voltage options include 24V for pallet jacks and walkie stackers, 36V for medium counterbalance trucks, 48V for heavy-duty reach trucks and order pickers and 80V for large counterbalanced forklifts.
How Long Does a Forklift Battery Last?
The longevity of a forklift battery depends on battery type and how well it’s maintained. Lead-acid batteries typically deliver 1,000 to 1,500 charge cycles, which translates to roughly three to five years in a single-shift operation. Lithium-ion batteries reach 2,000 to 3,000 cycles, approximately eight to 10 years of service. Proper maintenance is the single biggest factor in reaching those numbers. For lead-acid batteries showing reduced capacity, reconditioning can restore performance.
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How to Extend the Life of Your Forklift Battery
The right maintenance habits are what separate a battery that reaches its full cycle life from one that falls short. Here are the five practices that matter most.
Watering
Lead-acid batteries lose water through evaporation during each charge cycle. Check water levels every five to 10 charges, and add distilled water according to manufacturer instructions. Overwatering and underwatering both cause irreversible damage.
Washing
Corrosive buildup on battery terminals degrades performance and shortens overall battery life. Clean battery tops monthly with water and a battery acid neutralizer to prevent corrosion that can damage the casing and connectors. Burns Industrial Equipment offers professional on-site battery washing for fleets that prefer to leave the maintenance to the experts.
Charging
Charge lead-acid batteries when capacity drops to 20–30% and always allow the full cycle to complete. Keep the battery compartment and cover open during charging to ensure proper ventilation. Lithium-ion batteries handle opportunity charging well, making short top-off charges during breaks a practical option.
Equalization
Lead-acid batteries need periodic equalization, a controlled overcharge that breaks up sulfate buildup on the battery plates and rebalances electrolytes. Most manufacturers recommend equalizing every five to 10 charges. The process takes longer than a standard charge, so plan it accordingly.
Temperature
Never charge a battery that has exceeded 115°F. Extreme cold also reduces battery performance. If your operation runs in cold storage or freezer environments, ask about batteries designed for those conditions.
Get the Right Forklift Battery With Burns Industrial Equipment
Burns Industrial Equipment stocks a full inventory of industrial batteries and chargers from trusted brands including GNB, Hawker, Deka and OneCharge. Our battery and charger service technicians serve operations throughout Western Pennsylvania, Northeast Ohio and West Virginia, providing expert battery selection, inspection and testing, mobile repair, on-site washing and reconditioning services.
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Serving Western Pennsylvania, Northeast Ohio and West Virginia. Request battery service for your fleet or explore our full lineup of industrial batteries and chargers.
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