In 2023, companies put in more than two million orders for forklifts, according to statistics from the Industrial Truck Association. Many of those forklifts run off batteries, making efficient forklift battery recharging a big part of smooth operation.

How long does it take to recharge a forklift battery, though? What factors determine how fast you can get up and running again? Your business needs that lifter truck, so how do you keep it going?

While the question has a consistent answer, your charging technique and maintenance practices affect the process. In this article, we’ll demystify the process, so keep reading for everything you want to know about forklift batteries.

How Long Does It Take to Recharge a Forklift Battery?

The average battery seen in Class I, II, and III forklifts takes about eight hours to reach a full charge from near-depletion. Appropriate charging procedures need much more time than that, though.

Once charged, forklift batteries need to cool. Safe operation requires a cooling period about as long as the charge period.

For this reason, almost all companies use an 8-8-8 cycle for forklift battery recharging time. After eight hours of use, the battery charges for eight hours and cools for eight hours.

Battery Watering

If you’re new to dealing with forklifts, thinking about watering a battery can seem foreign. Why would you mix electricity and water?

The type of battery used in a forklift (called a lead-acid battery) requires water in each cell to ensure the materials within the battery mix well. As you use the forklift, the water level lowers. A low water level leads to wear and tear and can reduce the forklift battery lifespan in your truck.

Your charging practices should also include occasional watering. Ensuring that you include watering in week-to-week maintenance will keep your battery charging.

How Often to Water

At the start of a battery’s life, most batteries can go a little longer than a week between waterings. Near the end of its life, that number will dip lower.

As a general rule, expect to water your battery each week. Some batteries can work well for two weeks without watering, but doing so each week will build better habits for you and your work crew.

Good Watering Practices

When you water your battery, use these forklift battery maintenance tips. Violating these principles will wear out your battery faster.

  • Water after charging unless the water level drops low enough to expose metal plates
  • Use pure water to avoid damaging the battery with foreign debris
  • Invest in a single-point watering system to improve consistency
  • Avoid exposing batteries to freezing temperatures during watering or charging

The Myth of “Quick-Charging”

Don’t try to “top up” your battery with a brief plug-in period. The types of batteries common in modern forklifts don’t take well to partial charges, which will lead to battery replacement sooner rather than later. Unless an emergency demands you move your forklift, always let your battery get a complete charge and cooling cycle once you plug it in.

Think of your forklift battery as having a lifetime limit on the number of times you can charge it rather than the amount of charge it holds. If you charge the battery twice a day, you’ll cut its usable lifespan in half.

Depending on the manufacturer, quick-charging or opportunity-charging may void the battery’s warranty. 

Over-Discharge

Excessive discharge can also damage your battery. The ideal time to stop using a forklift battery comes when the charge sits around 20%.

If you have a single-shift operation, stop forklift use once you reach this threshold. If you use multiple batteries each day to keep the same forklift running between shifts, swap them between 20 and 30%.

Battery Swapping

Even though swapping batteries occurs often in multi-shift operations, don’t change batteries mid-shift. If you replace your battery halfway through a shift for reasons other than battery failure, you’ve wasted one of those valuable opportunities to charge it to completion.

Uncharged Batteries

Aim to have as little downtime for any specific forklift battery as possible. A used battery shouldn’t sit around waiting for a charge for more than about a day unless an emergency demands it.

Steps to Charge Your Lead-Acid Battery

When you need to recharge a forklift battery, steps need to flow in the same order every time. Consistent practices ensure long-term health and safety for you, your employees, and your equipment.

  • Turn the forklift off after driving it to the designated charging location
  • Ensure that no personnel or loads remain on the forklift
  • Wear personal protective equipment to avoid acid burns
  • Use your company’s battery removal equipment, such as a pallet jack or another lift truck, to remove the battery
  • Place the battery on the charging rack until it reaches a full charge
  • End charging once the battery reaches maximum charge, as overcharging damages the battery
  • Allow the battery to cool for its manufacturer-listed cooling period
  • Check water and electrolyte levels and adjust as needed
  • Return the battery to the forklift and ensure all connections are secure

Alternative Battery Options

While lead-acid batteries remain common, a growing number of forklifts use lithium-ion batteries. These batteries work the same way as the batteries in your laptop, cell phone, or electric car.

Some of the rules about appropriate battery charging and storage still apply to lithium-ion batteries. Unlike a lead-acid battery, however, a lithium-ion battery can benefit from opportunity charging and charges much faster than its lead-acid counterpart. If you have concerns about the added maintenance steps involved in dealing with water and electrolytes, consider a lithium-ion battery instead.

Charging Forward

Assuming you use a lead-acid battery, the answer to “How long does it take to recharge a forklift battery?” clocks in at eight hours, or twice that if you add cooling time. As long as you stick to best practices for charging, that should remain true for the life of your battery.

At SIP, we know forklifts and other lifter trucks inside and out. We value your time and have a strong commitment to ensuring you have every tool you need when you need it. Whether you’re trying to figure out what forklift suits your business, need repairs, or need forklift training, contact us today and we’ll set you up.