1. By Forklift Class and Application
| Forklift Class | Typical Voltage | Typical Battery Weight | Used In |
|---|---|---|---|
| Class I – Electric counterbalance (3 or 4 wheels) | 36V or 48V | 1,500–4,000 lbs (680–1,800 kg) | Warehouses, loading docks |
| Class II – Narrow aisle trucks | 24V or 36V | 1,000–2,000 lbs (450–900 kg) | Retail, distribution centers |
| Class III – Electric pallet jacks, walkies | 24V | 400–1,200 lbs (180–540 kg) | Ground-level stock movement |
2. Forklift Battery Case Sizes (US Standard)
Battery case sizes are often standardized. Examples include:
| Size Code | Dimensions (inches) | Dimensions (mm) |
|---|---|---|
| 85-13 | 38.75 × 19.88 × 22.63 | 985 × 505 × 575 |
| 125-15 | 42.63 × 21.88 × 30.88 | 1,083 × 556 × 784 |
| 155-17 | 48.13 × 23.88 × 34.38 | 1,222 × 607 × 873 |
Tip: The first number often refers to Ah capacity, and the next two refer to compartment size (width/depth) or number of cells.
3. Common Cell Configuration Examples
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24V system – 12 cells (2V per cell)
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36V system – 18 cells
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48V system – 24 cells
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80V system – 40 cells
Each cell can weigh around 60–100 lbs (27–45 kg) depending on its size and capacity.
4. Weight Considerations
Forklift batteries serve as counterweights, especially for electric counterbalance forklifts. That’s why they are intentionally heavy:
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Too light = unsafe lifting/stability.
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Too heavy = risk of damage or improper handling.
5. Lithium vs. Lead-Acid Battery Sizes
| Feature | Lead-Acid | Lithium-Ion |
|---|---|---|
| Size | Larger and heavier | More compact |
| Weight | 800–6,000+ lbs | 300–2,500 lbs |
| Maintenance | Requires watering | Maintenance-free |
| Energy Efficiency | 70–80% | 95%+ |
Lithium batteries can often be half the size and weight of an equivalent lead-acid battery with the same capacity.
Real-World Example:
A 48V 775Ah forklift battery:
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Dimensions: approx. 42" x 20" x 38" (107 x 51 x 97 cm)
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Weight: ~3,200 lbs (1,450 kg)
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Used in: Large Class I sit-down electric forklifts
Post time: Jun-20-2025
