by Theodore Taylor, on Feb 28, 2025 7:52:44 AM
Seventy percent of new forklifts sold in the U.S. are battery-powered, and experts predict that number will continue to grow. As more operations make the switch to electric forklifts, we thought it was a good time to answer some commonly asked questions such as:
- What type of forklift battery should I use?
- Which charging method is best?
- How do I make sure my batteries last as long as possible?
This article answers the topics above and more. If there’s something we didn’t cover or if you have other questions, please contact us online or by phone (800) 226-2345.
Fork Truck Batteries
Currently, about 80% of electric forklifts use lead-acid batteries, but that’s changing rapidly. Lead-acid batteries require extra maintenance and handling, so many operations are opting to use TPPL or lithium-ion batteries instead.
Lithium-ion batteries provide longer run times, have a longer lifespan and are virtually maintenance-free, but they cost more upfront. You can read more about both options in the articles below. The upshot is: if you run a multi-shift operation, TPPL and lithium-ion batteries will save you a lot of time and money.
- Are Lithium-Ion Forklift Batteries Right For Your Business?
- Thin Plate Pure Lead (TPPL) Batteries vs. Lithium-Ion Batteries: Which is Best?
Forklift Battery Maintenance
Note: TPPL and lithium-ion batteries don’t require regular maintenance, the information below applies to lead acid batteries only.
Why do forklift batteries need water?
Lead acid forklift batteries use a sulfuric acid electrolyte which needs to stay at a certain dilution level. If the electrolyte dilution gets out of balance, or if the battery plates dry out, you won’t get consistent voltage.
Water also regulates the battery’s temperature by dissipating heat. Without enough water, the battery can overheat and fail.
How often should forklift batteries be watered? Water levels should be checked every five cycles.* If the plastic battery element can be seen in several cells, the fluid should be topped off with pure or distilled water, not tap water. Also, forklift batteries should only be watered after the battery has been charged.
*Older forklift batteries need to be watered more frequently.
What is equalization charging and why is it necessary?
An equalization charge helps remove sulfate build-up and equalizes the power outputs of individual battery cells. This is important because:
- Sulfate build-up reduces the battery’s capacity
- When cells have different power inputs, it reduces the overall voltage
- Both issues reduce runtime
To equalize a lead acid forklift battery, you leave it plugged in for an extended period. For example, if you normally charge the battery for eight hours, the equalization charge might take eleven hours. Always follow manufacturer guidelines.
Many operations equalization charge over the weekend, but (again) it’s important to check the manufacturer guidelines. The age, type, size and usage affect how often a forklift battery needs an equalization charge.
DOWNLOAD our T.I.P.s (Toyota Information Partners)
for proper battery care.
How to Extend Forklift Battery Life
Properly maintaining a lead-acid battery is the best way to ensure it lasts as long as possible. Something else you can do is ask operators to delay charging the battery until it reaches 30-35%.
Battery life is limited by charging cycles, not hours or years. This holds true for all forklift battery types, including lead acid, lithium-ion and TPPL. By maximizing your utilization of every charge, you’ll maximize the life of your battery.
Important: don’t let the forklift battery drop below 20%. This low state of charge can damage the battery.
An average lead acid battery lasts about 1500 charging cycles. It doesn’t matter if the battery charges up from 35% or 75%. Every time you plug it in, the battery loses a “life.”
Lithium-ion batteries can last up to 3000 cycles and have the longest lifespan of all three battery options. Even a multi-shift operation can use the same lithium-ion battery for 5-7 years. In part because if you don’t charge a lithium-ion battery all the way to 100%, it doesn’t “count” as a full charge, just a partial charge.
A lithium-ion battery can recharge up to 80% during lunch breaks and shift changes, plenty of juice for the next shift. Because the battery wasn’t charged up to 100%, it doesn’t “cost” a full charging cycle. This is one of the many reasons we recommend lithium-ion batteries for multi-shift operations.
Forklift Battery Charging
There are three primary ways to charge forklift batteries:
- Conventional
- Opportunity
- Fast Charging
Standard lead acid batteries are designed to be conventionally charged but they can be charged using opportunity and fast charge profiles. The batteries would need to be fitted with monitoring devices to manage heat, monitor electrolyte levels, and amperage throughput. Even with the addition of the monitoring devices the overall lifespan of the lead acid battery will be reduced when opportunity and fast charging. Some customers have opted to purchase additional batteries to avoid the reduced lifespan, but they are then faced with the infrastructure cost of battery changing systems.
The hassle of battery swapping is why most multi-shift operations use lithium-ion or TPPL forklift batteries. Both can be opportunity charged during breaks or shift changes.
TPPL batteries cost less than lithium-ion batteries, but don’t last as long. They are, however, great for cold storage environments.
Lead acid batteries are not designed to be opportunity charged or fast charged. Cutting a charging cycle short or not allowing enough time for the battery to cool down can damage the battery and equipment. You can invest in a fast charge system, but it will shorten the life of your batteries.
Learn more about forklift battery charging methods and which option might be best for your operation.
Before Buy Your Next Electric Forklift, Consider This:
Experts predict by 2029:
- More than 62% of new electric forklifts sold in the U.S. will use lithium-ion batteries
- Only 33% will ship with lead-acid batteries
- 4% will use hydrogen fuel cells
If you don’t currently own any electric forklifts, we can help you calculate the benefits of choosing a lead acid or lithium-ion battery-powered forklift. Fork trucks with traditional lead acid batteries cost less, but you also have to buy charging, changing and watering equipment. We’re happy to provide different cost estimates so you can make an informed decision.
Contact us online, by phone at (800) 226-2345 or in person at one of our ten locations throughout Georgia and Florida
GEORGIA: Albany, Macon, Midland, Valdosta
FLORIDA: Jacksonville, Ocala, Orlando, Lakeland, Tampa, Winter Haven
Related Reading:
How to Maximize the Life of Your Forklift Batteries
All forklift battery articles
3 Common Misconceptions About Electric Forklifts
All electric forklift articles
