What You Need to Know
Electric forklifts – or e-forklifts for short – are indispensable in modern logistics. They are quiet, emission-free , and ideal for use in warehouses or on sensitive floors. More and more companies are using electrically powered industrial trucks in the rental sector. But anyone renting a forklift or electric forklift should know: The traction battery (the energy storage unit ) is the heart of the system – and often its weak point when it comes to charging.
This guide explains how to properly charge and maintain forklift batteries in rental operations , the different battery types available, typical charging times , and how simple routines can improve battery maintenance , safety , and lifespan. When implemented correctly, this extends the battery's lifespan and keeps it ready for use .
What distinguishes electrically powered forklifts and industrial trucks
Unlike diesel or gas forklifts, an electric forklift runs purely on electricity – powered by a traction battery (usually 24, 48, or 80 volts). This offers advantages, especially indoors and on sensitive floors:
- No CO₂ emissions – ideal for indoor areas, emission-free
- Quieter operation – more pleasant for employees
- Less maintenance work on the drive system – no oil, no exhaust fumes
- Easy charging via battery charging station ( s) in the charging area
Renting an electric forklift is particularly worthwhile for temporary assignments – provided the battery and charger are compatible and the charging process is safely organized. Nothing works without electricity – neither forklifts nor pallet trucks nor other industrial trucks .
Why maintenance, charger and charging area are crucial for charging
The battery is more than just a power source: it determines operating time, performance, and safety. When charging, remember to plan charging times , pay attention to the remaining charge , avoid overheating, and set up the charging station correctly. Errors during charging and discharging can lead to:
- reduced operating time and frequent recharging
- Deep discharge or overcharging – both can damage the battery.
- Faults in plug connections , chargers or the battery charging station
Important: Gases can be produced during the charging process (with lead-acid batteries) – therefore, ventilation and fire protection in the charging area are mandatory. This significantly reduces the risk of fire and explosion .
Battery types at a glance: proper charging according to battery type
Different battery types have different rules for charging, discharging, and maintenance. An overview of the most important battery types :
| Battery type | Allowed to load intermediate loads? | Maintenance / Special Features | Loading times |
|---|---|---|---|
| Lead acid |
 |
Water level check (electrolyte), full charge recommended; gassing occurs during charging → good ventilation necessary. | 6–12 hours |
| gel | |
Low maintenance (no refilling required), but sensitive: ideally discharge only to approx. 60% depth of discharge, avoid deep discharge | 6–10 hours |
| Lithium-ion |
 |
Intermediate charging allowed, no water refilling; modern chargers and BMS efficiently control the charging process. | 1–3 hours |
Charging cycles, lifespan, and why charging correctly is crucial
How long a forklift battery lasts depends heavily on charging , discharging, and environmental conditions. Guideline (depending on usage, temperature, and maintenance):
- Lead-acid batteries : approx. 1,500–2,500 charging cycles , typical lifespan approx. 3–5 years
- Gel batteries : approx. 2,000–3,000 charging cycles , typical lifespan approx. 4–6 years
- Lithium-ion batteries : approx. 3,000–4,000 charging cycles , typical lifespan approx. 6–10 years ; intermediate charging can extend the lifespan.
Incorrect charging can significantly shorten these values – especially through deep discharge, high temperatures (°C) or unsuitable chargers.
5 tips: How to charge forklift batteries safely and efficiently in everyday rental operations
1. Avoid deep discharge: Understand residual charge and voltage in detail
Don't start with too little charge . As a rule of thumb in everyday rental situations: don't drive further if the charge drops below 20% , but charge in good time. With lead-acid batteries , it becomes critical when individual cells fall below approximately 1.75 V per cell . For a 48V traction battery, this roughly corresponds to a range of about 30–32 V (depending on the battery design and measuring point).
What happens during deep discharge? Lead sulfate forms during discharge. If the battery is discharged too deeply and then not recharged properly or promptly, hard crystals can form (sulfation). These crystals can sometimes no longer be activated during recharging – the capacity permanently decreases, the battery loses range, and the battery's lifespan is drastically reduced. A single deep discharge can already cause damage; after weeks of deep discharge, recovery is often no longer possible.
2. Battery and charger: only use compatible chargers.
Only use the compatible charger from the rental package or an approved device when charging. Incorrect chargers (incorrect charging curve, voltage, current) increase the risk of overcharging , overheating, and damage to the battery. Modern chargers recognize battery types, control the charging process, and protect the connectors – but only if the battery and charger are compatible.
3. Intermediate charging and charging times: depending on the battery type
Lithium-ion batteries are designed for intermediate charging – short intermediate charges (e.g., during breaks) keep electric vehicles ready for use for longer and can extend their lifespan. For lead-acid batteries, however, the rule is: charge the battery fully whenever possible and avoid partial cycles. For gel batteries, additionally note: do not discharge too deeply (approximately 60% depth of discharge). Charging times depend on the charger, the battery's condition, the temperature, and the charging range.
4. Maintenance & Electrolyte: Check water level correctly (only for lead-acid systems)
Maintenance is crucial for lead-acid batteries : Do not check the water level before charging, but at least 30 minutes after charging is complete . The reason: water can evaporate during the gassing phase; the level will be inaccurate immediately after charging. In everyday rental situations, this is usually once a week (depending on usage). Use only distilled water . Gel batteries are generally maintenance-free (no topping up required).
Ensure that the charging area is free of grease and oil – contamination increases risks with electrical energy and can cause contact problems.
5. Battery charging station, ventilation and fire protection: Setting up the charging station correctly
The charging area is a safety zone. Always charge on firm, dry ground, with clear markings of the charging area and a safe distance from flammable materials . Lead-acid batteries can release gases during charging: hydrogen can escape – poor ventilation increases the risk of explosion . Therefore: ensure adequate ventilation , keep ignition sources away, and implement consistent fire protection measures .
Temperature: Ideally, the temperature should be around 5–35 °C . Overheating (e.g., >45 °C) increases the risk of damage; below 5 °C, performance and charging efficiency decrease. During charging, check the plug connections: clean, dry, and undamaged – contact problems can generate heat and increase the risk of fire and explosion.
DGUV Information, Occupational Safety and Safety Regulations for Loading
When operating forklifts and other industrial trucks , clear regulations from occupational safety and the DGUV (German Social Accident Insurance) rules apply. The DGUV's basic principles for safe operation are particularly relevant (e.g., DGUV Principle 308-001 for training/appointment). The key point is that only trained and appointed personnel may operate forklifts, and typical hazards (e.g., during charging, with battery types, and during the charging process) must be part of the training.
For charging, this means: defining safety regulations in the charging area, taking DGUV information into account, clarifying responsibilities, and clearly marking the charging point (battery charging station(s)). Additionally, requirements from the Occupational Health and Safety Act and company regulations (building technology, fire protection concept) must be observed.
Personal protective equipment during the charging process: safety glasses, etc.
When charging – especially lead-acid (electrolyte) batteries – appropriate personal protective equipment is essential. The minimum standard in the charging area is safety goggles . Depending on the setup, protective gloves and suitable clothing may also be necessary. Furthermore, ensure that antistatic requirements are met and that the charging area is dry and free of oil/grease.
What to do if problems occur while loading?
The battery in a rental device from BIBERGER is tested and ready for use. However, should something go wrong during charging or use (e.g., unusual charging times, charger malfunction, suspected deep discharge):
- Stop the forklift immediately
- Report errors by phone or via our chat
- We will provide a replacement or send a technician.
Our service team is familiar with all types of electric forklifts – whether front forklifts, reach trucks or four-wheel models – and checks chargers, plug connections, battery type and charging point.
Mandatory training (DGUV): safe handling of forklifts, batteries and charging process
The safe operation of electrically powered industrial trucks is not optional: instruction and authorization are part of occupational safety obligations (DGUV/Occupational Safety and Health Act). In our SYSTEM-CARD training courses, you will learn how to handle electric forklifts and batteries safely – including battery types, correct charging, typical charging times, risks such as deep discharge, and proper conduct in the charging area.
Conclusion: Regularly charge the battery correctly – safely and efficiently in rental operations
Electric forklifts are economical, quiet, and reliable – provided the battery, charger, and charging area are compatible. Monitor the remaining charge, avoid deep discharge, charge according to the battery type, keep the charging station clean and well-ventilated, and observe all applicable safety and occupational health and safety regulations. This ensures the forklift remains operational , operates efficiently , and proper maintenance extends the lifespan of the traction battery.
Do you want to rent an electric forklift that runs reliably? Then BIBERGER is the right place for you.
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