The battery is the part of an electric forklift that buyers most often forget to cost, and it is the part that decides whether the truck is cheaper than an engine-powered one.
Cost it per hour, not per unit
A replacement battery is a large single number, which makes it feel like a one-off event. It is not: it is a running cost paid in advance. Spread it:
Battery cost per hour = replacement cost / (life in years x annual hours)That figure belongs alongside your energy and maintenance cost per hour. Our operating cost calculator does this automatically once you enter the replacement cost and the expected life.
Lead-acid and lithium-ion behave differently
The database records the battery type where the manufacturer states it. The practical differences:
- Lead-acid costs less to buy, needs watering and equalisation charges, does not like partial charging, and generally needs a cool-down period. Multi-shift work usually means a second battery and a changing station.
- Lithium-ion costs more to buy, needs no watering, tolerates opportunity charging during breaks, and typically lasts more cycles. Where it removes the need for a spare battery and a battery room, the higher price can be recovered on floor space and labour alone.
Comparing the two on purchase price only will always favour lead-acid and will often be the wrong answer. Compare cost per hour across the expected life instead.
The weight trap
On a counterbalance truck the battery is structural ballast. Spec sheets state a minimum battery weight; fitting a lighter pack reduces the truck’s rated capacity. This catches people out when replacing a lead-acid pack with a lighter lithium-ion one – which is why lithium conversions often need ballast added. Check the minimum battery weight row on the model page before assuming any pack will fit.
What affects battery life
Depth of discharge, charging discipline, temperature and maintenance all shorten or extend it. Rather than guessing, ask your supplier what life they expect in your duty cycle and enter that figure. If they will not commit, run the calculator twice – once optimistic and once pessimistic – and see whether the decision changes. If it does, the difference is worth negotiating over.
Budget it properly
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