Custom Lithium Forklift Batteries, 24V to 80V
LiFePO4 replacement packs for walkie pallet trucks, stackers, reach trucks and counterbalance forklifts. Built to your truck’s battery compartment, counterweight requirement, connector and charger, so the switch from lead-acid is a battery change, not a truck redesign.
Forklift systems we build for
Voltage follows the truck class. Capacity, tray dimensions, connector and charger interface are matched to the truck you are converting or the model you are building.
| Truck type | System voltage | What drives the design | Reference packs |
|---|---|---|---|
| Walkie pallet jacks, end and centre riders, walkie stackers | 24V | Compact tray, frequent short trips, opportunity charging | 24V 210Ah 24V 315Ah |
| Narrow-aisle and stand-up counterbalance trucks | 36V | Lift height, mast hydraulics, fit in the existing compartment | Custom design |
| Counterbalance forklifts | 48V | Shift energy, counterweight, charger compatibility | 48V 315Ah 48V 460Ah |
| Heavy-duty counterbalance trucks | 80V | High lift loads, long shifts, large compartments | 80V 460Ah |
Replacing a lead-acid forklift battery: how to size it
Do not copy the lead-acid amp-hour rating. A flooded lead-acid battery should only be discharged to about 80%, needs a full charge and a cool-down after every shift, and loses usable capacity at high current. A LiFePO4 pack can use about 90% of its capacity, keeps its voltage under load, and can be topped up at every break. Size from the energy the truck actually uses between charging opportunities.
- Existing battery: 48V 600Ah flooded lead-acid, discharged to 80% per shift →
48 × 600 × 0.8 ≈ 23 kWhused per shift - Lithium option: 51.2V 460Ah →
23.6 kWhrated,≈ 21 kWhusable at 90% - Energy needed for two shifts:
2 × 23 ≈ 46 kWh - Top-up charging at 0.5C:
230 A × 51.2 V × 0.5 h ≈ 5.9 kWhper 30-minute stop. Two breaks per shift plus a 30-minute charge at shift change gives5stops - Energy available over two shifts:
21 + 5 × 5.9 ≈ 50.5 kWhagainst 46 kWh needed; full recharge overnight
Counterweight: the detail most conversions miss
On a counterbalance forklift the battery is part of the counterweight, and the truck’s data plate states a minimum battery weight. A LiFePO4 pack of the same energy is much lighter than lead-acid, so a straight swap can reduce the truck’s rated capacity and stability.
We design the steel tray with ballast so the finished pack meets the minimum weight on the data plate and sits in the same position as the original battery. The tray dimensions, lifting points and connector position match the compartment, so no truck modification is needed.
Where the cost difference actually comes from
Flooded lead-acid
- About 1,500 cycles with good maintenance
- About 8 hours of work, then 16 hours to charge and cool
- 24/7 operation typically needs three batteries per truck
- Watering, equalising, a ventilated charging room and battery-change equipment
- Voltage drops as it discharges; trucks slow down late in the shift
LiFePO4
- Over 3,000 cycles
- Charges in the truck at breaks; no cool-down and no swap
- One battery per truck for multi-shift work
- Sealed, no watering, no acid or gassing
- Steady voltage to the end of the shift
Lithium costs more per battery, but labour, spare batteries and charging-room space usually decide total cost per shift. More: How to Choose the Right Forklift Battery.
What we engineer into a forklift pack
- Cells and modules
- Prismatic LiFePO4 cells in a rigid module structure, compressed and fixed against the vibration and shocks of dock plates and floor joints.
- BMS and truck interface
- CAN or RS485 to the truck controller and charger where the truck supports it; state of charge on a display for trucks that do not. Current limits are set to the traction and pump controllers.
- Charger
- A lithium charger matched to the pack’s voltage and charge rate, or confirmation that your existing charger can be reprogrammed with a lithium profile. Lead-acid profiles with equalisation must not be used.
- Connector and cabling
- The same battery connector as your truck, so charging points and trucks do not change.
- Cold stores
- Heated packs with temperature-gated charging for freezer operation; see charging at low temperatures.
- Standards
- Industrial truck batteries are commonly assessed against IEC 62619 and UL 2580, and the truck’s electrical system against EN 1175 in Europe. Which reports cover your exact design, and what your truck maker requires, is confirmed at quotation.
Lead time and order quantity
From a locked specification: samples in 12–15 working days when cells are in stock, 20–25 when cells must be sourced; production in 30–35 working days. From the first design conversation: about 4 weeks for a finalised design with no new tooling, 8–12 weeks for a typical custom project, 14–18 weeks when certification is in scope. How each phase works: custom battery pack development process and our manufacturing capabilities.
Forklift battery questions
Can I use my existing lead-acid charger?
Will a lithium battery change my truck’s lifting capacity?
Is opportunity charging bad for a lithium forklift battery?
How long does a lithium forklift battery last?
Do you supply batteries for AGVs and tuggers too?
Further reading
Send your forklift battery details
An engineer replies with questions or a proposed configuration. The more of this list you can share, the faster we can quote:
- Truck make, model and class
- Current battery voltage, Ah and tray dimensions
- Minimum battery weight from the data plate
- Connector type
- Shifts per day and break pattern
- Charger model, or need a new charger
- Operating temperature, including cold stores
- Number of trucks