A Complete Guide to Electric Forklifts and Their Battery Systems

As global warehousing, manufacturing, and logistics industries continue to modernize, electric forklifts are rapidly replacing internal-combustion models. These machines offer lower operating costs, higher energy efficiency, and cleaner working environments. At the heart of every electric powered forklift lies its battery system, which determines the truck’s runtime, lifting power, and long-term reliability. Selecting the right battery for each forklift type—and each application scenario—is essential for maximizing efficiency and safety.

Below is a comprehensive breakdown of different battery powered forklift truck types, their voltage platforms, and how companies can choose the right energy system for real-world operations.

1. Types of Electric Forklifts and Their Application Scenarios

1. Electric Pallet Trucks

• Typical Voltage: 24V or 36V

• Common Use Cases: Short-distance material handling, warehouses, supermarkets, factory production lines

• Key Features: Compact size, frequent start-stop cycles

• Battery Recommendation:
  Lightweight 24V lithium battery systems optimized for fast opportunity charging and zero maintenance.

 

2. Counterbalance Electric Forklifts

• Typical Voltage: 48V or 80V

• Use Cases: Loading/unloading, container operations, heavy pallet transport

• Key Features: Medium-to-heavy lifting, long operating hours

• Battery Recommendation:

  • 48V lithium systems for 1.5–3.5 ton forklifts

  • 80V high-power lithium battery packs for 4–8 ton heavy-duty electric forklifts

Lithium solutions provide stable voltage output throughout the shift, avoiding the performance drop commonly seen in lead-acid batteries.

3. Reach Trucks

• Typical Voltage: 48V

• Use Cases: High-bay racking, cold storage, narrow-aisle warehouses

• Key Features: Precision lifting, low-temperature environments

• Battery Recommendation:
  48V LiFePO₄ batteries with excellent low-temperature performance and stable discharge curves.

 

 

4. Three-Wheel Forklifts & VNA Trucks

• Typical Voltage: 36V / 48V

• Use Cases: Narrow aisles, high-density storage

• Key Features: Tight turning radius, strict weight-balance requirements

• Battery Recommendation:
  Custom-fit lithium modules ensuring optimal center-of-gravity and heat management.

 

5. Tow Tractors & Electric Stackers

• Typical Voltage: 24V / 36V / 48V

• Use Cases: Factory internal logistics, assembly lines, order picking

• Key Features: Long-distance operation, high energy consumption

• Battery Recommendation:
  High-capacity lithium battery packs enabling long runtime and fast recharging.

 

2. Understanding Voltage Platforms in Electric Forklifts

 

3. Why Lithium Batteries Are the Preferred Choice for Modern Electric Forklifts

Modern battery powered forklift trucks are increasingly using lithium instead of traditional lead-acid batteries due to:

✔ Fast Charging

1–2 hours to reach 80%, ideal for multi-shift operations.

✔ Longer Lifespan

Up to 4,000 cycles, often matching the forklift’s full service life.

✔ Zero Maintenance

No watering, no acid cleaning, no dedicated charging rooms.

✔ High Energy Efficiency

95%+ charging efficiency significantly reduces electricity costs.

✔ Environmentally Safe

No lead, no acid, and fully recyclable.

These advantages make lithium batteries the standard for next-generation electric powered forklifts.

Baufar Battery: Professional Lithium Solutions for All Electric Forklift Types

Baufar Battery specializes in industrial-grade lithium power systems designed to replace traditional lead-acid batteries in all major electric powered forklift brands, including:

Toyota, Yale, Linde, Hyster, Crown, Heli, Hangcha, Doosan, CAT, and more.

Why companies choose Baufar Battery:

• Uses A-grade LiFePO₄ cells from reputable global suppliers

• Automotive-grade BMS with real-time protection

• Supports all voltage platforms: 24V / 36V / 48V / 80V

• OEM replacement available for all electric forklift models

• Global technical support for installation and service