What drives conversion cost
- Voltage and capacity. A 24V pack for a pallet jack costs far less than an 80V pack for a heavy-duty truck. Capacity in amp-hours is the other half — more shifts per charge means a bigger, pricier pack.
- The charger. Lithium charges on a different profile than lead-acid, so a conversion almost always includes a new charger matched to the pack.
- Installation and integration. Sizing the pack to the compartment, matching counterweight, and confirming the truck's electrical system is compatible. Some trucks need adapters or tray work.
- Battery management system (BMS). The electronics that monitor cells, manage temperature, and protect the pack. It is built into the battery, not a separate line item — but it is part of why lithium packs cost more than lead-acid.
Typical market ranges
The ranges below are typical market figures commonly reported by industry suppliers — not quotes, and not prices for your truck. Final pricing depends on voltage, capacity, charger, and installation, and the only real number is a dealer quote for your specific truck.
| Cost component | Typical range |
|---|---|
| Lithium battery pack (24V–80V) | $12,000 – $35,000+ |
| Charger with lithium profile | $2,500 – $7,000 |
| Installation & integration | $1,000 – $3,000 |
| Total conversion, per truck | $15,000 – $45,000+ |
Smaller trucks and lower voltages sit at the bottom of those ranges; heavy-duty 80V trucks sit at the top. Multi-truck fleets are quoted per truck, and dealers may price the fleet as a package.
Where the money comes back
A conversion costs more up front than a like-for-like lead-acid replacement. It earns that back in multi-shift operations: no battery swaps mid-shift, no watering labor, opportunity charging during breaks, and a longer service life than lead-acid. Single-shift operations with time for charging and watering often do better staying with lead-acid. Read our lithium conversion guide for the full comparison before you decide.
Conversion cost questions, answered
Why is there no fixed price for a lithium conversion?
Every conversion is sized to one truck: its voltage, compartment dimensions, counterweight needs, and how many shifts it runs. Two 48V trucks can need very different packs. The ranges on this page are typical market figures reported by industry suppliers — your dealer's quote for your specific truck is the only real number.
Do I need a new charger with a lithium conversion?
Yes, in almost every case. Lithium batteries charge on a different profile than lead-acid, and the charger must match. The charger is a real part of the conversion cost — see the ranges below.
When does a lithium conversion pay for itself?
It pays fastest in multi-shift operations: no battery swaps, no watering labor, opportunity charging during breaks, and a longer service life than lead-acid. Single-shift operations with time for charging and watering often do better staying with lead-acid. A dealer can run the numbers for your shift pattern.
Can any forklift be converted to lithium?
Most modern electric forklifts can, but not all. The dealer checks voltage, compartment fit, counterweight, and whether the truck's electrical system is compatible. An honest dealer will tell you when a truck is not a good candidate.
What happens to my old lead-acid battery?
Dealers typically remove it when they install the lithium pack, and spent lead-acid batteries go to recycling — lead is one of the most recycled materials in the world. Ask about core credit when the dealer quotes you.