Warehouse Reach Truck Lithium Battery
Industrial-grade LiFePO4 battery engineered as a direct drop-in replacement for lead-acid batteries in narrow-aisle reach trucks. Built for multi-shift operations demanding high energy density, zero maintenance, and fast opportunity charging.
Key Features
Extended Cycle Life: Delivers 3,500 to 4,000 cycles at 80% Depth of Discharge (DoD) while retaining over 80% initial capacity.
Opportunity Charging: Supports high-current charging up to 1C, enabling full recharge during standard operator breaks (15–30 minutes) without memory effect or electrolyte outgassing.
Intelligent BMS Protection: Real-time cell monitoring for over-voltage, under-voltage, short-circuit, over-current, and high/low temperature extremes (-20°C to 55°C operating range).
CANbus Communication: Integrates via standard CAN 2.0B protocols to transmit real-time State of Charge (SoC), temperature, and fault diagnostics directly to truck instrumentation panels.
Maintenance-Free Design: Eliminates daily water refilling, terminal cleaning, and equalization charges, reducing routine labor overhead.
Technical Specifications
|
Technical Parameter |
Specification Range |
|
Nominal Voltage |
24V / 36V / 48V / 80V (Customizable) |
|
Capacity Range |
200Ah to 1000Ah |
|
Cell Chemistry |
Lithium Iron Phosphate (LiFePO4 / LFP) |
|
Maximum Discharge Current |
Up to 3C (Pulse) / 1C (Continuous) |
|
Charging Voltage |
29.2V (24V system) to 96.8V (80V system) |
|
Recommended Charge Current |
0.5C |
|
Operating Temperature (Charge) |
0°C to 45°C |
|
Operating Temperature (Discharge) |
-20°C to 55°C |
|
Communication Interface |
CANbus 2.0B, RS485 |
|
Enclosure Protection |
IP54 / IP67 (Optional for cold storage) |
Product Overview
Designed to replace traditional 24V, 36V, 48V, and 80V lead-acid batteries in electric reach trucks without mechanical alterations. Maintains exact physical dimensions and counterweight requirements specified by OEM chassis designs (such as Raymond, Crown, LeeBull, and Jungheinrich models). Features modular prismatic LiFePO4 cells, integrated laser-welded busbars, and a heavy-duty steel enclosure finished with acid-resistant industrial powder coating.
Compatibility & Applications
Compatible Equipment Types: Stand-up and sit-down reach trucks, narrow-aisle order pickers, and high-lift pallet stackers.
Chassis Integration: Matches OEM battery compartment tolerances down to ±1mm. Engineered to replicate exact lead-acid counterweight distributions to preserve truck stability curves and steering geometry.
Terminal Configuration: Heavy-duty Anderson power connectors and customized copper terminal lugs matched to truck wiring harnesses.
Customization Options
Physical Dimensions: Custom steel casing fabrication to fit non-standard or legacy forklift battery compartments.
Electrical Parameters: Voltage and capacity scaling tailored to specific duty cycles and run-time requirements.
Counterweight Ballasting: Internal steel plate ballasting added to match exact weight requirements of replaced lead-acid units.
Peripherals: Integrated heating films for cold storage/freezer environments (-30°C operation), automatic watering system ports (if required by spec), and custom display monitors.
Quality Control & Testing
Every battery pack undergoes rigorous testing protocols before dispatch.
Cell Sorting & Matching: Internal resistance and capacity matched within ±1% variance prior to module assembly.
Electrical Testing: 100% full-load discharge and charge efficiency testing, internal short-circuit simulation, and BMS cut-off verification.
Environmental Stress Screening: Vibration table testing (simulating rough warehouse flooring transport) and thermal chamber cycling (-20°C to 60°C).
Traceability: Laser-etched serial numbers on cells and packs linked to raw material batch records and test logs.
Compliance Standards: UN38.3, CE, UL2580 / UL1973 cell and pack level compliance, and ISO 9001 certified manufacturing facility. Test reports provided with each shipment.
Packaging & Shipping
Packaging Construction: ISPM 15 compliant heat-treated wooden crates with internal high-density EPE foam blocking to prevent shifting during transit.
Hazmat Compliance: Packed and labeled in accordance with UN3480 Class 9 hazardous materials regulations for lithium-ion batteries.
Global Logistics Terms: Flexible export shipping support, including FOB, CIF, and DDP shipping options tailored to international distribution channels.
Documentation: MSDS, UN38.3 test summary, Bill of Lading, and Certificate of Analysis supplied for air, sea, and overland freight clearance.
FAQ
Q: Can this lithium battery directly replace my existing lead-acid battery without modifying the reach truck?
A: Yes. We build the battery to match the exact physical length, width, height, and weight of your existing lead-acid trough, ensuring direct drop-in installation and proper counterweight balance.
Q: How does the BMS communicate with older reach truck models that lack CANbus integration?
A: We offer independent external LCD fuel gauges that display State of Charge (SoC), voltage, and fault alerts directly in the operator's line of sight, bypassing the need for truck-side CAN integration.
Q: Is opportunity charging safe for LiFePO4 batteries during shift changes?
A: Yes. LiFePO4 chemistry permits partial, high-current charging without memory degradation. Operators can plug the truck in during 15-minute breaks without harming battery lifespan.
Q: How do you ensure the battery weight matches the minimum counterweight requirement of my reach truck?
A: During the configuration stage, we calculate the exact weight of your legacy lead-acid battery and integrate certified internal steel ballast plates to ensure the truck's stability and tipping safety thresholds remain compliant.
Q: What is the typical lead time for standard and customized orders?
A: Standard models ship within 15 to 20 business days. Fully customized enclosures or non-standard voltage/capacity configurations require 25 to 30 business days following drawing sign-off.
Q: What quality documents are included with the shipment?
A: Each shipment includes a factory inspection report, individual cell matching logs, UN38.3 test summary, warranty card, and user/maintenance manuals.
Request A Quote
To receive an accurate technical proposal, shipping terms (FOB/CIF/DDP), and pricing within 24 hours, please provide the following details:
1.Reach Truck Make and Model:
2.Target Operating Voltage (V):
3.Required Capacity (Ah):
4.Battery Compartment Dimensions (L x W x H in mm):
5.Required Battery Weight (kg):
6.Annual Order Quantity / Fleet Size:
7.Destination Port / Delivery Location:
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