Compact Lithium Battery for Pallet Trucks
Drop-In LiFePO4 Power Solutions & Retrofit Packs for Electric Pallet Jacks & Walkie Stackers
Engineered for Class 3 electric material handling equipment, this drop-in lithium replacement for 24V pallet jacks and walkie stackers utilizes automotive-grade LiFePO4 (LiFePO4) prismatic cells and an integrated Hardware/Software BMS.
Built as a direct replacement for traditional flooded or AGM lead-acid tubs, the system eliminates daily water maintenance, supports rapid opportunity charging, and drops into existing battery compartments without requiring structural modifications or truck rewiring.
Standard Voltage Classes: 24V / 36V / 48V
Capacity Range: 50Ah to 280Ah (custom configurations available for specific OEM footprints)
Primary Application: Electric pallet trucks, motorized hand trucks, and low-lift warehouse walkie stackers.
Key Features
High-Current Discharge Capability: Supports up to 1C continuous discharge and 2C peak discharge to handle sudden motor startup surges, heavy load lifting, and ramp climbing without voltage sag.
Extended Cycle Life: Delivers over 3,500 cycles at 80% Depth of Discharge (DoD) at 25°C, yielding a 5-to-8-year operational lifespan in multi-shift fulfillment centers.
Opportunity Charging Support: Accepts high-current fast charging (0.5C - 1C). Operators can top off the LiFePO4 battery for walkie stacker fleets during 15-minute breaks without memory effect or electrolyte degradation.
Multi-Level BMS Protection: Hardware and software protection against over-voltage, under-voltage, short circuits, and thermal runaway. Features cell-balancing algorithms to maintain pack voltage equilibrium.
Thermal Management: Integrated structural-grade aluminum housing and optional internal heating films for reliable operation in cold-chain and refrigerated warehousing environments down to -20°C.
Technical Specifications
|
Technical Parameter |
Specification Range |
Notes / Conditions |
|
Nominal Voltage |
24V / 48V |
Customizable to OEM controller specs |
|
Rated Capacity |
50Ah – 280Ah |
Measured at 0.2C discharge rate (25°C) |
|
Energy Density |
140Wh/kg - 160Wh/kg |
Optimized for compact compartment weight limits |
|
Cell Chemistry |
LiFePO4 (LiFePO4) |
Prismatic cells, UL1642 certified |
|
Continuous Discharge Current |
100A – 200A |
Model-dependent |
|
Peak Discharge Current |
300A (30 seconds) |
Handles motor startup surges |
|
Standard Charging Current |
0.5C |
Recommended for max lifespan |
|
Max Charging Current |
1.0C |
Fast-charge protocol enabled |
|
Communication Protocol |
CAN 2.0B / RS485 |
Integrates with truck dashboard/controller |
|
Operating Temperature |
Charge: 0°C to 45°C; Discharge: -20°C to 60°C |
Low-temp heating option available |
|
Enclosure Material |
Q235 Steel / Aluminum Alloy |
Powder-coated, IP54 ingress protection |
Compatibility & Applications
Target Equipment: Electric pallet jacks, walkie stackers, order pickers, and small tow tractors across brands such as Crown, Raymond, and Jungheinrich.
Mechanical Integration: Custom laser-cut steel enclosures engineered to match OEM battery tray dimensions, weight distribution, and center-of-gravity requirements.
Terminal & Interface: Heavy-duty Anderson power connectors (SB175 / SB350) and waterproof aviation plugs for CAN communication wiring.
Retrofit Compatibility: Directly replaces 6-cell or 12-cell flooded/AGM lead-acid tubs without altering truck charging infrastructure or lift mechanics.
Customization Options
We support end-to-end OEM/ODM customization based on specific industrial truck platforms:
Mechanical Dimensions: Custom length, width, height, and terminal placement to match specific battery compartment tolerances (±0.5mm).
Electrical Configuration: Voltage adjustments from 12V to 80V; capacity scaling through parallel cell arrangements.
Communication & Telematics: Customized CANopen or J1939 communication maps to feed real-time State of Charge (SoC), State of Health (SoH), and fault codes to fleet management systems.
Housing & Protection: Heavy-gauge steel plate thickness adjustments, custom lifting lug positioning, and IP65 waterproof ratings for wash-down environments.
Quality Control & Testing
Manufacturing is executed on automated pack assembly lines utilizing laser welding systems, pneumatic cell clamping fixtures, and multi-channel programmable aging cabinets.
Standard Factory Test Protocols:
Cell Sorting: Internal Resistance (IR) matched within ±1mΩ and resting voltage matched within ±5mV.
BMS Functional Test: Automated testing of current limiting, active balancing current, and thermal cut-off thresholds.
Pack Aging Test: 100% full charge/discharge cycle testing under simulated industrial load before final casing.
Safety Compliance: Certified to UN38.3, CE, and RoHS standards. Full test reports (including vibration, drop, and thermal shock validation) are available upon request for QA review.
Packaging & Shipping
Packaging Method: UN-certified plywood boxes lined with anti-static EPE foam and moisture-barrier bags to prevent shifting during transit.
Shipping Classification: Class 9 Hazardous Materials (Dangerous Goods). Shipped in strict compliance with UN3480 / UN3481 regulations.
Documentation Provided: MSDS, UN38.3 Test Summary, Commercial Invoice, Packing List, and Certificate of Origin (Form E/COO available upon request).
FAQ
Q: Can this lithium battery directly replace my existing lead-acid battery without changing the truck's charger?
A: Yes, provided the existing charger output voltage and CC/CV charging profile match the lithium requirements. However, for optimal lifespan and BMS synchronization, we recommend using a dedicated lithium charger with CAN communication.
Q: How do you ensure the physical dimensions fit our specific pallet truck model?
A: We require the exact battery compartment inner dimensions (Length x Width x Height) and terminal orientation blueprints. Our engineering team generates a 3D STEP model for your review and sign-off before sample production.
Q: What is the standard lead time for samples and volume production?
A: Standard sample production takes 7 to 12 working days. Batch production orders (50–500 units) typically require 25 to 30 days, depending on custom enclosure requirements.
Q: How does the BMS handle low-temperature warehouse environments (e.g., cold storage)?
A: For cold-chain applications, we integrate a low-temperature internal heating film. The BMS automatically draws power from the external charger to warm the cells above 0°C before allowing charging current to enter, preventing lithium plating.
Q: What data can be transmitted through the CAN bus protocol?
A: The CAN 2.0B interface transmits real-time pack voltage, individual cell voltages, current, temperature, SoC, SoH, and active error flags (such as over-temperature or under-voltage warnings) directly to the vehicle display.
Q: What warranty terms and after-sales support do you provide?
A: We offer a standard 3-year or 5,000-hour performance warranty (whichever comes first). Technical support, remote diagnostics via BMS log analysis, and replacement parts are managed directly by our engineering team.
Request a Quote
To receive an accurate engineering evaluation and quotation, please provide the following details:
Equipment Brand & Model Number: e.g., Crown, Raymond, Jungheinrich pallet truck series
Target Voltage & Capacity: e.g., 24V 200Ah
Battery Compartment Inner Dimensions: Length x Width x Height in mm
Existing Charger Specifications: Output voltage and current rating
Estimated Annual Quantity & Delivery Terms: FOB / CIF / EXW
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