A battery-powered forklift, the dominant type in modern indoor warehouses.
Detailed Definition
An electric forklift is a lift truck powered by an electric motor, usually running on a lead-acid or lithium-ion battery, and in some fleets on hydrogen fuel cells. Electric trucks include sit-down and stand-up counterbalanced models, reach trucks, order pickers and other narrow aisle trucks, and walk-behind pallet jacks and stackers. They produce no exhaust at the point of use and run quietly, which is why they are widely used indoors, in food and cold storage, and in retail distribution. On counterbalanced models the heavy battery also serves as part of the counterweight.
Battery choices for electric forklifts
Lead-acid batteries have long been the standard. They need regular watering, a full charge and cool-down cycle, and a ventilated charging area because charging gives off hydrogen. Multi-shift operations often swap batteries between shifts. Lithium-ion batteries need no watering, can be opportunity charged during breaks, and usually stay in the truck, but they cost more up front. Hydrogen fuel cells refuel in minutes but need hydrogen supply and dispensing equipment. The right choice depends on shifts, duty cycle and site infrastructure.
Safety and rules that apply
- OSHA 29 CFR 1910.178 covers powered industrial trucks, including electric models: operator training, evaluation at least once every three years, and safe operation.
- The same standard addresses changing and charging storage batteries, including facilities for flushing spilled electrolyte, fire protection and ventilation.
- Battery weight and type must match what the truck's data plate allows, because the battery is part of the truck's stability.
- Check the capacity plate for the actual load center and lift height.
Electric trucks still need daily pre-shift checks of forks, chains, brakes, horn and steering.
Related Glossary Terms
Frequently Asked Questions
Can electric forklifts be used outdoors?
Many can be used outdoors on dry, paved surfaces, and some models are built with pneumatic tires and sealed components for outdoor work. Standard indoor electric trucks with cushion tires and low ground clearance are not suited to gravel, mud, steep ramps or standing water. Check the manufacturer's rating for the operating environment, and consider weather protection for the battery and electrical components if the truck will often work outside.
Is it safe to charge lead-acid forklift batteries inside the warehouse?
It is common, but the charging area must be set up for it. OSHA rules for powered industrial trucks require designated battery charging areas with facilities for flushing and neutralizing spilled electrolyte, fire protection, protection of charging equipment from damage by trucks, and adequate ventilation to disperse fumes from gassing batteries. Smoking and open flames must be kept away. Follow the battery and charger manufacturer's instructions as well.