An electric forklift powered by lithium-ion batteries, offering longer life and faster charging than lead-acid.
Detailed Definition
Lithium-ion forklifts use battery packs with built-in battery management systems instead of flooded lead-acid batteries. They are usually charged in short opportunity charging sessions during breaks and do not need watering or equalizing charges, which can remove the need for battery change-outs on multi-shift operations. Packs for counterbalanced trucks are often ballasted to meet the truck's minimum battery weight, because the battery forms part of the counterweight. See electric forklift.
Converting a lead-acid fleet to lithium-ion
Many electric trucks can run either chemistry, but the change should be planned with the truck manufacturer or dealer.
- Confirm the replacement pack is approved for the truck model and meets the minimum battery weight on the nameplate.
- Check that charger, connectors and truck controls work with the pack's battery management system.
- Plan charger locations so operators can opportunity charge without blocking aisles or exits.
- Update operator training on charging routines, which differ from lead-acid change-outs.
Safety and site considerations
OSHA 29 CFR 1910.178 includes requirements for battery charging areas and battery handling, many of them written around lead-acid batteries and acid spills. Lithium-ion packs avoid acid handling and the hydrogen gassing of lead-acid charging, but they carry their own risks if damaged, overheated or charged improperly. Follow the manufacturer's instructions, inspect packs and cables for damage, and include battery fires in emergency planning with input from your fire protection provider and insurer. Keep the pack's documentation, including its approvals and charging limits, with the truck's records, and use only the charger specified for that pack.
Related Glossary Terms
Frequently Asked Questions
Do lithium-ion forklift batteries need a battery room?
Lead-acid battery rooms exist largely for ventilation of hydrogen gas, eyewash and acid spill control, and battery changing equipment. Lithium-ion packs do not vent hydrogen in normal charging and are usually charged in place on the truck, so many sites charge them at stations near work areas. Local fire codes, insurer requirements and the manufacturer's instructions still apply, so confirm charging location rules before removing a battery room.
Are lithium-ion forklifts suitable for cold storage?
They are used in cold storage, but performance and charging depend on the pack design. Cold temperatures reduce available capacity, and many lithium-ion cells should not be charged below certain temperatures without heating. Some packs are built for freezer use with insulation or heaters. Tell the supplier your lowest operating and charging temperatures and duty cycle, and ask for documented performance at those conditions.