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Product Overview

 

 

Heavy-duty LiFePO4 battery systems engineered to replace traditional lead-acid (AGM/GEL) batteries in electric pallet jacks, walkie stackers, and low-lift warehouse trucks. Built for multi-shift warehouse operations, these drop-in 24V lithium-ion pallet jack batteries deliver stable voltage under heavy loads, eliminate daily watering and acid maintenance, and support rapid opportunity charging during breaks. Manufactured in-house with strict cell sorting and automated pack assembly to ensure consistent fleet performance.

 

 
 
Key Features

 

Chemistry & Life Cycle:

Grade-A Lithium Iron Phosphate (LiFePO4) prismatic cells delivering >= 3,500 cycles at 80% Depth of Discharge (DoD) at 25°C.

01

BMS Protection:

Integrated hardware and software Battery Management System monitoring individual cell voltage, pack temperature, short-circuit, over-charge, and deep-discharge.

02

Charging Efficiency:

Supports 1C fast charging; reaches 80% charge within 45 to 60 minutes, enabling seamless multi-shift operations without battery swapping.

03

Constant Power Output:

Maintains flat discharge voltage above 22V (for 24V systems) until near-depletion, preventing hydraulic pump speed reduction under heavy pallet loads.

04

Cold Storage Resilience:

Optional internal low-temperature heating film enables safe charging and discharging down to -20°C in refrigerated warehouses.

05

 

 

Technical Specifications

 

 

Specification

Standard 24V Model (Typical)

Custom Fleet Options

Nominal Voltage

24V (25.6V operating)

12V to 48V

Rated Capacity

105Ah / 210Ah

50Ah - 400Ah

Total Energy

2.68 kWh / 5.37 kWh

Up to 10.2 kWh

Dimensions (L x W x H)

Custom-engineered to OEM compartment specs

Tailored to exact tray drawings

Weight

~28 kg to 55 kg (Matches lead-acid ballast weight)

Optimized per truck counterweight balance

Max Continuous Discharge

100A - 200A

Scalable to motor controller draw

Max Charge Current

100A (1C)

Configurable via charger profile

Communication Protocol

CAN 2.0B / RS485 (Integration with truck display)

Custom OEM protocols available

Operating Temperature

Charge: 0°C to 45°C / Discharge: -20°C to 60°C

Integrated heating for sub-zero environments

 

Compatibility & Applications

 
 
01
 

Target Equipment:

Walkie pallet jacks, rider pallet trucks, low-lift order pickers, and automated guided vehicles (AGVs).

 
02
 

Major Truck Brand Compatibility:

Fits battery compartments of leading MHE brands (e.g., Raymond, Crown, Toyota, Hyster-Yale, Jungheinrich) via modular steel enclosure designs.

 
03
 

Mechanical Fit:

Exact match to original OEM battery tray dimensions, terminal positions, and securing anchor points. No structural truck modification required.

Lithium Ion Batteries In Forklifts

 

Customization Options

Enclosure & Dimensioning:

Heavy-gauge welded steel housing tailored to exact millimetre tolerances for specialized or legacy truck models.

Terminal Configuration:

Flexible cable lengths, Anderson connectors (SB175/SB350), or OEM-specific plug types.

Communication Integration:

Customized CAN bus data mapping to communicate State of Charge (SoC), fault codes, and temperature directly to the truck dashboard display.

Battery Management:

Configurable low-voltage cutoff thresholds and pre-charge circuits tailored to specific motor controller requirements.

 

 

Quality Control & Testing

 

 

Cell Sorting:

100% capacity grading and internal resistance matching prior to pack assembly.


Weld Inspection:

Automated laser welding for busbars, followed by micro-ohm resistance testing on all electrical connections.

BMS Functional Testing:

Simulated over-current, short-circuit, and thermal runaway response testing on every assembled unit.

Factory Acceptance Testing (FAT):

3-hour full charge/discharge cycling under rated load before packaging.

Compliance & Documentation:

Each batch ships with UN38.3 test summaries, MSDS, CE certification, and individual test reports covering internal resistance and capacity verification.

 

 

Packaging & Shipping

Packaging Construction: UN-certified hazardous materials plywood boxes lined with high-density anti-static foam to prevent transit shock.
State of Charge for Shipping: Shipped at 30% SoC in compliance with international maritime and air dangerous goods regulations.
Transport Documentation: Complete Dangerous Goods (DG) declaration paperwork provided for Class 9 UN3480 lithium-ion battery shipments.

Li-iron Forklift Battery

 

 

fAQ

 

 

Q: Can this battery directly replace my existing lead-acid pallet jack battery?

A: Yes. Physical dimensions, terminal placements, and weight distributions are engineered to match original lead-acid trays, allowing direct drop-in installation without counterweight adjustments.

Q: Do I need to replace my existing industrial charger?

A: Most traditional lead-acid chargers are incompatible due to different charging algorithms. We supply matched high-frequency lithium smart chargers or provide CAN communication parameters for integrated onboard charging systems.

Q: How does opportunity charging affect battery lifespan?

A: Unlike lead-acid batteries, LiFePO4 chemistry suffers no memory effect and incurs zero capacity degradation from partial, short-duration charging during lunch breaks or shift changes.

Q: What happens if the battery temperature drops below freezing in cold storage?

A: Standard units disable charging below 0°C to protect cell structure. For cold storage operations, select our low-temperature variant equipped with an automatic internal pre-heating circuit activated prior to charging.

Q: Can the BMS communicate with our fleet management software?

A: Yes. The onboard BMS supports standard CANopen and RS485 protocols, transmitting real-time voltage, current, temperature, and SoC data to truck controllers or external telemetry devices.

Q: What is the standard lead time for bulk orders and custom enclosures?

A: Standard catalog models ship within 15 to 20 business days. Custom enclosure designs requiring new tooling or specialized CAN protocols typically require 30 to 40 days, including sample approval.

 

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Request a Quote

MOQ Policy: 1 sample unit accepted for evaluation and fleet testing prior to bulk manufacturing.
To evaluate this drop-in 24V lithium-ion pallet jack battery solution for your fleet, please provide the following technical parameters:
Equipment Brand & Model Number: (e.g., Crown WP Series / Raymond WL)
Target Voltage & Capacity: (e.g., 24V, 210Ah)
Battery Compartment Inner Dimensions (L x W x H):
Required Connector Type: (e.g., Anderson SB175)
Operating Environment: (Standard warehouse / Freezer -20°C)
Order Quantity & Delivery Destination:

 

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