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Home > NEWS > Industry News > Lead-Acid or Lithium on a 10 m Scissor: Five-Year Math

Lead-Acid or Lithium on a 10 m Scissor: Five-Year Math

Update time : 2026-11-06
Reviewed by the Hontylift engineering team · 5 min read

The purchase price difference is not the argument. The shift pattern is. A one-shift factory machine and a two-shift rental unit will give opposite answers on the same two options, and both answers are correct.

We fit both on the same scissor lift chassis, and we quote both. What follows is the arithmetic we use in front of a customer, with the numbers we can defend.

24V 200Ah lead acid versus lithium scissor lift battery

A lead-acid pack and a lithium pack compared side by side.

What is actually in the machine

The standard pack on our 10 m (32 ft) and 12 m (40 ft class) electric scissor lifts is four 6 V blocks at 200 Ah, wired for 24 V. That is 4.8 kWh nominal. The charger is 24 V / 30 A, which means a full recharge from empty takes a little over six and a half hours in theory and seven to eight hours in practice once you allow for the taper at the end of the cycle.

That single number, seven to eight hours, sets the shape of the whole argument. A scissor lift cannot work two shifts on one pack if the pack needs most of the night to recharge, and that is true whether the chemistry is lead-acid or lithium. What changes is how much of the pack you are allowed to use.

Usable capacity is the number that matters

A lead-acid pack is normally discharged to 50% before recharging, because deeper cycles shorten its life sharply. So 4.8 kWh nominal gives about 2.4 kWh of working energy. A lithium iron phosphate pack of the same nominal rating is routinely taken to 80%, which gives about 3.8 kWh, and it does not object to being topped up at lunchtime.

In practice that is the difference between a machine that finishes a shift at 40% and one that finishes at 15%. Operators do not care about the chemistry. They care about whether they can finish the job without a charge, and the lithium machine usually can.

Cycle life, converted into years

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Lead-acid in this application is good for roughly 1,200 to 1,500 cycles at 50% depth. Lithium iron phosphate is quoted at 3,000 to 5,000 cycles at 80% depth by the cell makers, and our field experience is consistent with the lower end of that when machines work in heat.

UsageHours per yearLead-acid pack lifeLithium pack life
One shift, 4 h of drive and lift per day, 250 days1,0004 to 5 yearsLonger than the machine
One long shift, 7 h per day1,7502.5 to 3 years8 to 10 years
Two shifts, 10 h per day with a mid-day charge2,5001.5 to 2 years, and unreliable in the second6 to 8 years

The two-shift row is the one that decides most purchases. Replacing a lead-acid pack every eighteen months turns a cheap scissor lift into an expensive one, and it also means the machine is out of service for a day each time, which the maintenance budget never accounts for.

Five-year cost, as an index

Absolute prices move, so we quote this as a 2026 index with the lead-acid scissor lift at 100. It covers the pack, the replacement packs, and the charging energy, on a two-shift pattern.

ItemLead-acidLithium
Machine with pack100118 to 126
Replacement packs over five years22 to 30, two replacements0
Charging energyIndex 100Index 86 to 92, because the charger taper wastes less
Downtime for pack changes2 days0
Five-year index122 to 130118 to 126

On two shifts the two options land within a few points of each other, and the lithium machine wins on uptime rather than on cash. On one shift, lead-acid wins clearly, because the pack outlives the comparison and the extra capital buys nothing. That is the whole decision, and it is why we do not recommend lithium as a default.

Where lithium loses

Four places, and buyers should hear them before they choose:

  • Cold charging. A lithium pack must not be charged below 0 degrees C, and a lead-acid pack charged below zero sulphates. Neither chemistry likes a Russian winter, but lithium needs a heated pack or a warm indoor charge point, which is a site requirement rather than a machine feature. Our cold weather notes cover the routine.
  • Repair skill. A battery is a battery until a BMS fails, and then it is electronics. A workshop that can swap a lead-acid block in an afternoon may not be able to diagnose a BMS, and the whole pack becomes the spare part.
  • Fire perception. Insurers and facility managers in some markets treat a lithium machine indoors differently from a lead-acid one, regardless of the actual risk profile of an iron phosphate pack. If your customer's risk department has a policy, find out before the order, not after.
  • Disposal. Lead-acid has a mature and paid-for recycling chain in most countries. Lithium does not, everywhere, yet. The cost of end-of-life sits with the last owner.

The decision line we use

Under four hours of actual drive and lift per day, indoors, above 5 degrees C: lead-acid. It is cheaper to buy, cheaper to repair, and the pack will outlive the first owner's interest in the electric scissor lift.

Two shifts, an opportunity-charging pattern, sub-zero sites, or a rental fleet where uptime is the product: lithium. The capital difference pays back inside three years on the two-shift pattern, and the machine stays available while the lead-acid unit is on charge.

Everything in between is a judgement about your charging infrastructure, which we cannot see from here. Tell us the shift pattern and the charge window and we will run the index for your case rather than ours. Send us the two numbers and we will reply with the model and the pack we would fit, including the case where the answer is the cheaper one.

Need this on your site?

Send the working height, the load and the site constraint. An engineer replies with a model recommendation and a written quotation within one business day — or tells you it cannot be done.

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