Reach Truck Replacement Lithium Battery
Drop-in LiFePO4 replacement batteries engineered specifically for electric reach trucks and narrow-aisle warehouse equipment. Designed to match the exact physical dimensions, weight distribution, and terminal placement of legacy lead-acid traction batteries. Eliminates daily maintenance (watering and acid checks), supports high-rate opportunity charging, and delivers stable voltage output under heavy hydraulic lifting loads. Built through strict automated manufacturing processes, including automated cell sorting, precision laser welding, and comprehensive end-of-line electrical testing.
Key Features
Chemistry: Lithium Iron Phosphate (LiFePO4 / LFP) chemistry chosen for maximum thermal stability and chemical safety.
Cycle Life: ≥ 3,500 cycles at 80% Depth of Discharge (DoD) under nominal operating conditions.
Opportunity Charging: Supports high-current fast charging during 15–30 minute break periods without memory effect or electrolyte degradation.
Smart BMS Protection: Real-time cell-level voltage monitoring, over-temperature cutoff, short-circuit protection, over-discharge/over-charge prevention, and low-temperature charging restriction.
Heavy-Duty Construction: Heavy-gauge welded steel casing with structural reinforcement to withstand continuous vibration and vertical shock impacts in narrow-aisle warehouse operations.
Technical Specifications
|
Parameter |
Specification Range / Standard |
|
Nominal Voltage |
24V / 36V / 48V / 80V (Configurable to truck specs) |
|
Capacity Range |
200Ah to 900Ah |
|
Energy Capacity |
5.1kWh to 72kWh |
|
Cell Type |
Automotive-grade prismatic LiFePO4 cells |
|
Max Continuous Discharge |
Up to 2C (application-dependent) |
|
Charging Current (Recommended) |
0.5C to 1C fast charge capability |
|
Operating Temperature (Discharge) |
-20°C to 55°C (-4°F to 131°F) |
|
Operating Temperature (Charge) |
0°C to 45°C (Optional internal heating film for -30°C cold storage) |
|
Communication Protocol |
CAN 2.0B / RS485 (Integrates with truck dashboard diagnostics) |
|
Enclosure Protection |
IP54 / IP67 optional for wash-down or harsh environments |
Compatibility & Applications
Target Equipment: Electric reach trucks, narrow-aisle forklifts, order pickers, and counterbalanced trucks.
Direct Brand Compatibility: Engineered as direct drop-in replacements for standard battery compartments across major OEM platforms, including Raymond, Crown, Toyota, Hyster, Yale, and Jungheinrich.
Counterweight Match: Custom steel ballasting applied inside the battery housing to match the exact weight requirement of the original lead-acid battery, preserving truck stability triangle and steering axle load balance.
Connector Types: Anderson, REMA, and customized heavy-duty industrial connectors aligned with OEM truck wiring harnesses.
Customization Options
Physical Dimensions: Custom sheet metal enclosure fabrication to fit non-standard or restricted reach truck battery compartments.
Electrical Configuration: Voltage, Ah capacity, and discharge rate tailored to specific shift-duty cycles.
Terminal & Cable Placement: Custom cable length, exit points, and connector brand matching.
Communication Interface: Custom CAN bus parameter mapping for proprietary truck dashboard communication.
Quality Control & Testing
Cell Sorting: 100% incoming cell testing for internal resistance (IR) matching and capacity grading within a ±1% tolerance.
Weld Inspection: X-ray and automated optical inspection (AOI) on busbar laser welds to ensure low electrical resistance and high structural integrity.
Electrical End-of-Line (EOL) Testing: Automated burn-in testing, high-voltage insulation dielectric strength testing (AC withstand voltage), and full-load charge/discharge cycling.
Traceability: Unique laser-etched serial numbers on every pack linked to raw material batch reports, cell test data, and BMS parameter logs.
Certifications: UN38.3, CE, UL2580 (cell/module level), and RoHS compliant. Test reports available upon request.
Packaging & Shipping
Packaging: ISPM 15 compliant heat-treated fumigated wooden crates with internal shock-absorbing EVA foam bracing and moisture barrier bagging.
State of Charge (SoC): Shipped at standardized 30% SoC in compliance with international dangerous goods transport regulations.
Documentation: UN38.3 Test Summary, Material Safety Data Sheet (MSDS / SDS), Dangerous Goods Declaration (DGD), and Class 9 hazard labeling provided for sea and air freight.
FAQ
Q: Will this battery fit my specific reach truck model without altering the truck frame?
A: Yes. We build custom sheet metal enclosures matching the precise length, width, height, and weight of your original lead-acid battery tray, ensuring a drop-in installation for models from brands like Raymond, Crown, and Toyota.
Q: Do we need to change the existing truck charger?
A: Legacy lead-acid chargers are generally incompatible with lithium profiles. We supply matched high-frequency lithium smart chargers that communicate with the battery BMS or operate via preset voltage curves.
Q: Can the battery be charged during short breaks (opportunity charging)?
A: Yes. LFP chemistry has no memory effect, allowing high-current charging during 15-to-30-minute shifts or lunch breaks to sustain multi-shift operations without battery swapping.
Q: How does the battery perform in cold storage or freezer warehouses?
A: Standard discharge operates down to -20°C. For freezers operating down to -30°C, we integrate optional low-temperature internal heating films powered by the charger before charging commences.
Q: How is the correct counterweight balance maintained when replacing lead-acid with lighter lithium?
A: We integrate certified internal steel ballast plates into the battery enclosure to replicate the exact weight of the original lead-acid battery, maintaining the truck's stability triangle and steering axle load.
Q: What warranty and technical support do you provide?
A: We provide a 5-year or 10,000-hour performance warranty (whichever comes first), backed by remote BMS data diagnostics and modular component replacement support.
Request a Quote
To configure the correct replacement battery for your fleet, please provide the following details:
Forklift Brand & Model Number: (e.g., Raymond 7000 Series, Crown ESR Series)
Original Lead-Acid Battery Specs: Voltage (V) & Capacity (Ah)
Battery Compartment Inner Dimensions: Length × Width × Height (mm or inches)
Required Counterweight / Total Battery Weight:
Daily Operating Shift Count & Working Environment: (e.g., Ambient, Cold Storage -30°C)
Quantity & Delivery Destination (Port / Zip Code):
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