To size a forklift battery, match its amp-hours (Ah) to how long the truck must run between charges: estimate the energy a shift uses, then pick a pack with enough Ah to cover it with a margin. A single-shift operation usually runs one lead-acid pack and charges overnight. A multi-shift operation needs more capacity — a bigger lead-acid pack with a spare and a charge-and-swap routine, or a lithium pack that takes opportunity charges during breaks. Voltage sets the truck’s power; amp-hours set its run-time. This guide gives the steps to size a battery to your shift, and shows when lithium removes the swap. HONGLI’s electric forklifts ship with a lead-acid pack as standard, with a lithium upgrade for multi-shift work.
Size a battery in 4 steps (HowTo)
Decide how long the truck must run before it can charge (a shift, or until the next break). 2. Energy per hour — Estimate the draw from your duty: light pallet work draws less than heavy, continuous lifting. 3. Match the amp-hours — Choose a pack whose Ah covers the hours with a margin, so you do not run it flat. 4. Decide the charging method — Single-shift: one lead-acid pack, charge overnight. Multi-shift: a spare lead-acid pack, or lithium for opportunity charging.
Lead-acid or lithium for the shift
Lead-acid suits single-shift work with overnight charging. Multi-shift work needs either a second lead-acid battery and a swap routine, or a lithium pack you top up at breaks. Lithium removes the swap and the cool-down, at a higher up-front cost.
Definition
Voltage is the system’s power level; amp-hours (Ah) is its energy store, and therefore its run-time. Two batteries at the same voltage can run very different shifts depending on their Ah.
FAQ
How do I know what battery size I need?
Match amp-hours to your hours between charges, with a margin. Voltage sets power; Ah sets run-time.
Do I need a spare battery?
For multi-shift work on lead-acid, yes — or switch to lithium and top up at breaks instead.
Why does lithium suit multi-shift?
It takes fast opportunity charges with no swap and no cool-down, so the truck keeps running.
What does HONGLI fit?
A lead-acid pack as standard, with a lithium upgrade for multi-shift operations.
Related: /blog/lithium-vs-lead-acid-forklift-battery/ · /resources/knowledge-base/forklift-voltage-60v-72v-80v/ · /forklifts/electric-forklift/ · /get-a-quote/