How to Match a Material Handling Charger to the Battery You Want to Charge

When it comes to material handling equipment—whether forklifts, pallet jacks, aerial lifts, or tow tractors—selecting the correct charger for the battery is one of the most important decisions. A properly matched material handling charger not only ensures efficient charging but also extends battery life, reduces downtime, and improves overall safety. Choosing the wrong charger, on the other hand, can lead to poor performance, premature battery failure, or even safety hazards.

1. Match Charger Voltage to Battery Voltage

The first and most important rule is that the charger voltage must match the battery pack voltage.

  • A 24V charger must be paired with a 24V battery.

  • A 36V charger must be paired with a 36V battery.

  • A 48V charger must be paired with a 48V battery.

Using a charger with the wrong voltage rating will result in incomplete charging or potential battery damage.

2. Size the Charger to the Battery’s Amp-Hour Capacity

The charger’s output current should be properly sized for the amp-hour (Ah) rating of the battery.

  • For lead-acid batteries, the general rule is to size the charger at 10–20% of the battery’s Ah rating.

    • Example: A 500Ah battery requires a charger that delivers around 50–100 amps.

  • Charging too slowly increases downtime, while charging too quickly can cause overheating and shorten battery life.

For lithium batteries, it is critical to follow the manufacturer’s recommended charging current. While lithium batteries can accept faster charging, they still must remain within safe operating limits.

3. Chemistry Compatibility (Lead-Acid vs. Lithium)

Battery chemistry is a crucial factor when selecting a charger.

  • Lead-Acid Chargers use multi-stage charging (bulk, absorption, float) designed for flooded, AGM, or gel batteries.

  • Lithium Chargers use a constant current/constant voltage (CC/CV) profile and often communicate directly with the Battery Management System (BMS).

Using the wrong type of charger can cause permanent damage. A lead-acid charger may never shut down properly with a lithium battery, while a lithium charger without BMS communication may fail to operate safely.

4. Connectors and Communication

In material handling applications, batteries often use specialized connectors such as Anderson, SB, or DIN. The charger must be compatible with the battery’s connector type.

For lithium systems, many chargers now include CAN bus communication or other digital protocols to “handshake” with the battery’s BMS. Without this, charging may be incomplete or unsafe.

5. Match to the Application and Duty Cycle

The charger should also be matched to the way the equipment is used.

  • Single-shift operations: A standard charger is usually sufficient.

  • Multi-shift or heavy-use operations: Fast charging or opportunity charging may be required.

  • Lithium systems: Chargers designed for partial charge cycles maximize uptime and take advantage of lithium’s flexibility.

6. Environmental Considerations

Material handling chargers must also be suited to the environment in which they operate.

  • Indoor, climate-controlled warehouses: Standard chargers are usually adequate.

  • Cold storage or outdoor yards: Chargers should be rated for low-temperature operation.

  • High-dust or corrosive areas: Sealed or industrial-rated chargers provide longer service life.

Final Thoughts

Matching a material handling charger to the correct battery comes down to:

  1. Matching the voltage.

  2. Sizing properly for the amp-hour rating.

  3. Ensuring chemistry compatibility.

  4. Selecting the correct connector and communication method.

  5. Considering the application and environment.

The right charger doesn’t just recharge the battery—it protects the battery, maximizes uptime, and reduces long-term costs.

Please see our line of material handling battery chargers for more information!!

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