How to charge a forklift: guide to maintenance and required power

Electric forklifts, commonly called forklifts, have become an indispensable presence in warehouses, plants, and logistics centers. In recent years, they have replaced many internal combustion models, thanks to their obvious advantages: zero local emissions, reduced noise, and lower operating costs.

But the true beating heart of an electric forklift is the traction battery, the element that determines how many hours of work it can support, how reliable it will be over time, and how much it will cost to keep it operational.

Often, those who operate the forklift limit themselves to using it and recharging it, without knowing much about what happens inside the battery or how it should be treated. Yet, a little extra attention, even in small daily habits, can greatly extend the life of the accumulator and ensure greater efficiency for the entire warehouse.

How are forklift batteries made?

The battery installed on a forklift is not a mysterious “black box,” but a complex system made up of multiple cells connected together and enclosed in a sturdy container. The total weight varies greatly - from a few hundred kilograms for smaller forklifts to over a ton for heavy-duty lift trucks.

The most common battery technologies are:

Lead-acid batteries: the traditional choice, used for decades. They offer a good price-performance ratio and are available in a wide range of formats. Inside, lead plates are immersed in a liquid solution of sulfuric acid and distilled water.

Lithium (Li-ion) batteries: a more modern and high-performance option. They don’t require topping up, have faster charging times, and a longer lifespan (even over 3,000 cycles). They are also lighter for the same capacity and provide greater energy efficiency - though they remain more expensive.

Both solutions have their pros and cons, and the choice largely depends on how intensively the forklift is used and on the company’s operational needs.

Charging: AC plugs and DC plugs

One of the most practical and important aspects of battery management is charging. It’s not just a matter of “plugging it in” - proper devices and connectors are required to handle high currents safely.

On the power grid side (AC): to power the charger, industrial CEE sockets are typically used, either single-phase or three-phase, depending on the required power. In medium- and large-sized warehouses, three-phase sockets (red) are common, while smaller warehouses often use single-phase sockets (blue).

On the battery side (DC): this is where specific connectors come into play, such as REMA or Anderson, designed to withstand high currents without overheating.

These connectors are not interchangeable - each forklift uses a specific type, and following that specification ensures compatibility and safety.

For example, a REMA 320A plug will only be compatible with a REMA 320A socket.

What does TCE provide?

CE Group, for instance, supplies its chargers without plugs on either the AC or DC side, except for single-phase models, which come with a standard Schuko plug. For all other models, it’s the customer’s responsibility to specify the desired connectors when ordering, so that the plugs can be installed before delivery.

This is an important detail: it’s not uncommon for a company to receive a new charger and only discover at installation that the plug doesn’t match their power outlet or forklift fleet - a simple oversight that can halt operations and cause delays.

The practical advice is clear: always specify, at the time of ordering, both the available AC socket type at your facility and the DC plug type compatible with your forklifts.

As for the procedure, one golden rule applies: connect the DC plug to the battery first, then plug the AC connector into the power outlet. Never disconnect anything during charging, as this can damage both the battery and the charger.

How much energy is needed to charge a forklift?

The amount of energy required depends on the battery’s capacity, which varies significantly based on the forklift model. To estimate how much a forklift consumes, we can use a simple formula:

ENERGY = VOLTAGE (V) × CAPACITY (Ah)

In practice, just multiply the battery’s volts by its amp-hours. The result is expressed in watt-hours (Wh), which, when divided by 1,000, give kilowatt-hours (kWh) - the same unit used on electricity bills.

Maintenance: taking care to extend battery life

A neglected battery not only discharges faster but can also lose years of useful life. That’s why maintenance isn’t optional -it’s a fundamental part of managing a forklift efficiently.

For lead-acid batteries:

Regularly check the level of distilled water (always do this after charging, never before).
Refill only with distilled water, never with tap water, to avoid deposits and scaling.
Periodically clean the battery terminals and surface, removing dust and acid residues.
Avoid deep discharges - try not to drop below 20% of remaining charge.
Perform equalization cycles (long, balanced recharges) according to the manufacturer’s instructions.

For lithium batteries:

They do not require topping up or equalization.
It’s enough to check the condition of the cables and let the battery management system (BMS) do its job.
They offer greater flexibility for intermediate charging, without the risk of damage.

When to perform maintenance checks?

To keep a battery efficient at all times, it’s best to follow a clear routine:

Daily: quick inspection, cleaning of dirt and dust, and visual check of cables.
Weekly: check and top up the water level (only for lead-acid batteries).
Every 6–12 months: more thorough maintenance, preferably carried out by a qualified technician, including residual capacity measurement, connection checks, and safety testing.

Conclusion

The battery is not just an accessory - it is the very heart of the electric forklift. Autonomy, reliability, and operating costs all depend on it. Proper charging, the right choice of connectors, and consistent maintenance allow you to make the most of its potential and avoid costly downtime.

Taking care of the batteries means taking care of the entire warehouse operation. A good battery, treated with care, not only lasts longer but also ensures smooth, uninterrupted, and stress-free working days.