{"id":9004,"date":"2026-11-05T10:53:03","date_gmt":"2026-11-05T10:53:03","guid":{"rendered":"https:\/\/holobattery.com\/applications\/forklift-batteries\/"},"modified":"2026-11-05T10:53:03","modified_gmt":"2026-11-05T10:53:03","slug":"forklift-batteries","status":"publish","type":"page","link":"https:\/\/holobattery.com\/applications\/forklift-batteries\/","title":{"rendered":"Forklift Batteries"},"content":{"rendered":"<style id=\"hb-applications-css\">.page-header{display:none!important}main.site-main.page,main.site-main.page .page-content{max-width:none!important;width:100%!important;margin:0!important;padding:0!important}.hb-page{--ink:#0B141E;--body:#475569;--mut:#64748B;--line:#E2E8F0;--tint:#F8FAFC;--green:#23A455;--green-ink:#19763D;--green-wash:#ECFDF5;--dark:#0B141E;--on-dark:#CBD5E1;font-family:'Inter',-apple-system,BlinkMacSystemFont,\"Segoe UI\",Roboto,Arial,sans-serif;color:var(--body);font-size:16px;line-height:1.65;background:#fff}.hb-page *,.hb-page *::before,.hb-page 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*{transition:none!important}}<\/style>\n<div class=\"hb-page\"><header class=\"hb-hero on-dark\"><div class=\"hb-wrap\"><div class=\"hb-hero-grid\"><div><h1>Custom Lithium Forklift Batteries, 24V to 80V<\/h1><p class=\"hb-lead\"><strong>LiFePO4 replacement packs<\/strong> for walkie pallet trucks, stackers, reach trucks and counterbalance forklifts. Built to your truck&#8217;s battery compartment, counterweight requirement, connector and charger, so the switch from lead-acid is a battery change, not a truck redesign.<\/p><div class=\"hb-hero-cta\"><a class=\"hb-btn hb-btn-primary\" href=\"https:\/\/holobattery.com\/contact\/\">Send your truck and battery details<\/a><\/div><nav class=\"hb-toc\" aria-label=\"On this page\"><a href=\"#builds\">Reference builds<\/a><a href=\"#sizing\">Replacing lead-acid<\/a><a href=\"#weight\">Counterweight<\/a><a href=\"#cost\">Cost per shift<\/a><a href=\"#engineering\">Engineering<\/a><a href=\"#faq\">FAQ<\/a><\/nav><\/div><div class=\"hb-mosaic\"><a href=\"https:\/\/holobattery.com\/product\/custom-24v-210ah-electric-forklift-battery\/\"><img fetchpriority=\"high\" decoding=\"async\" src=\"https:\/\/holobattery.com\/wp-content\/uploads\/2024\/10\/custom-24V-210Ah-forklift-lithium-battery.png\" alt=\"24V 210Ah custom battery pack\" width=\"600\" height=\"600\" fetchpriority=\"high\"><span>24V 210Ah<\/span><\/a><a href=\"https:\/\/holobattery.com\/product\/custom-48v-315ah-electric-forklift-battery\/\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/holobattery.com\/wp-content\/uploads\/2024\/10\/custom-48V-315Ah-forklift-lithium-battery.png\" alt=\"48V 315Ah custom battery pack\" width=\"600\" height=\"600\" loading=\"lazy\"><span>48V 315Ah<\/span><\/a><a href=\"https:\/\/holobattery.com\/product\/custom-48v-460ah-electric-forklift-battery\/\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/holobattery.com\/wp-content\/uploads\/2024\/10\/custom-48V-460Ah-forklift-lithium-battery.png\" alt=\"48V 460Ah custom battery pack\" width=\"600\" height=\"600\" loading=\"lazy\"><span>48V 460Ah<\/span><\/a><a href=\"https:\/\/holobattery.com\/product\/custom-80v-460ah-electric-forklift-battery\/\"><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/holobattery.com\/wp-content\/uploads\/2024\/10\/custom-80V-460Ah-forklift-lithium-battery.png\" alt=\"80V 460Ah custom battery pack\" width=\"600\" height=\"600\" loading=\"lazy\"><span>80V 460Ah<\/span><\/a><\/div><\/div><\/div><\/header><nav class=\"hb-section-nav\" aria-label=\"Battery applications\"><div class=\"hb-wrap\"><a href=\"https:\/\/holobattery.com\/applications\/\">All applications<\/a><a href=\"https:\/\/holobattery.com\/applications\/marine-battery-packs\/\">Marine<\/a><a href=\"https:\/\/holobattery.com\/applications\/agv-mobile-robot-batteries\/\">AGV &amp; Robots<\/a><a href=\"https:\/\/holobattery.com\/applications\/forklift-batteries\/\" aria-current=\"page\">Forklifts<\/a><a href=\"https:\/\/holobattery.com\/applications\/golf-cart-lsv-batteries\/\">Golf Carts &amp; LSVs<\/a><a href=\"https:\/\/holobattery.com\/applications\/energy-storage-batteries\/\">Energy Storage<\/a><a href=\"https:\/\/holobattery.com\/applications\/drone-uav-batteries\/\">Drones &amp; UAVs<\/a><a href=\"https:\/\/holobattery.com\/applications\/cold-climate-commercial-vehicle-batteries\/\">Cold Climate &amp; Trucks<\/a><\/div><\/nav><section class=\"hb-sec\"><div class=\"hb-wrap\"><div class=\"hb-kpis\"><div><b>24\u201380V<\/b><span>Forklift systems in our catalogue<\/span><\/div><div><b>0.5C<\/b><span>Charge rate on our 24V 210Ah truck pack, for break-time top-ups<\/span><\/div><div><b>1C<\/b><span>Continuous discharge on the same pack<\/span><\/div><div><b>0<\/b><span>Watering, equalising or battery-room swaps<\/span><\/div><\/div><\/div><\/section><section class=\"hb-sec tint\" id=\"builds\"><div class=\"hb-wrap\"><h2 class=\"hb-sec-h\">Forklift systems we build for<\/h2><p class=\"hb-sub\">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.<\/p><div class=\"hb-tablewrap\" tabindex=\"0\" role=\"region\" aria-label=\"Forklift classes and reference packs\"><table class=\"hb-spec\"><thead><tr><th>Truck type<\/th><th>System voltage<\/th><th>What drives the design<\/th><th>Reference packs<\/th><\/tr><\/thead><tbody><tr><td>Walkie pallet jacks, end and centre riders, walkie stackers<\/td><td>24V<\/td><td>Compact tray, frequent short trips, opportunity charging<\/td><td><a href=\"https:\/\/holobattery.com\/product\/custom-24v-210ah-electric-forklift-battery\/\">24V 210Ah<\/a><br><a href=\"https:\/\/holobattery.com\/product\/custom-24v-315ah-electric-forklift-battery\/\">24V 315Ah<\/a><\/td><\/tr><tr><td>Narrow-aisle and stand-up counterbalance trucks<\/td><td>36V<\/td><td>Lift height, mast hydraulics, fit in the existing compartment<\/td><td>Custom design<\/td><\/tr><tr><td>Counterbalance forklifts<\/td><td>48V<\/td><td>Shift energy, counterweight, charger compatibility<\/td><td><a href=\"https:\/\/holobattery.com\/product\/custom-48v-315ah-electric-forklift-battery\/\">48V 315Ah<\/a><br><a href=\"https:\/\/holobattery.com\/product\/custom-48v-460ah-electric-forklift-battery\/\">48V 460Ah<\/a><\/td><\/tr><tr><td>Heavy-duty counterbalance trucks<\/td><td>80V<\/td><td>High lift loads, long shifts, large compartments<\/td><td><a href=\"https:\/\/holobattery.com\/product\/custom-80v-460ah-electric-forklift-battery\/\">80V 460Ah<\/a><\/td><\/tr><\/tbody><\/table><\/div><\/div><\/section><section class=\"hb-sec\" id=\"sizing\"><div class=\"hb-wrap\"><h2 class=\"hb-sec-h\">Replacing a lead-acid forklift battery: how to size it<\/h2><div class=\"hb-prose\"><p>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.<\/p><\/div><div class=\"hb-calc\"><div class=\"hd\">Worked example: 48V counterbalance truck, two shifts per day (illustrative numbers)<\/div><ol><li>Existing battery: 48V 600Ah flooded lead-acid, discharged to 80% per shift \u2192 <code>48 \u00d7 600 \u00d7 0.8 \u2248 23 kWh<\/code> used per shift<\/li><li>Lithium option: <a href=\"https:\/\/holobattery.com\/product\/custom-48v-460ah-electric-forklift-battery\/\">51.2V 460Ah<\/a> \u2192 <code>23.6 kWh<\/code> rated, <code>\u2248 21 kWh<\/code> usable at 90%<\/li><li>Energy needed for two shifts: <code>2 \u00d7 23 \u2248 46 kWh<\/code><\/li><li>Top-up charging at 0.5C: <code>230 A \u00d7 51.2 V \u00d7 0.5 h \u2248 5.9 kWh<\/code> per 30-minute stop. Two breaks per shift plus a 30-minute charge at shift change gives <code>5<\/code> stops<\/li><li>Energy available over two shifts: <code>21 + 5 \u00d7 5.9 \u2248 50.5 kWh<\/code> against 46 kWh needed; full recharge overnight<\/li><\/ol><div class=\"res\">Result: one <b>51.2V 460Ah<\/b> pack covers two shifts with about 10% margin, provided the truck charges at every break and at shift change. Lead-acid would typically need a second battery and a battery change. If your site cannot charge at breaks, size up instead.<\/div><\/div><\/div><\/section><section class=\"hb-sec tint\" id=\"weight\"><div class=\"hb-wrap\"><h2 class=\"hb-sec-h\">Counterweight: the detail most conversions miss<\/h2><div class=\"hb-prose\"><p>On a counterbalance forklift the battery is part of the counterweight, and the truck&#8217;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&#8217;s rated capacity and stability.<\/p><p>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.<\/p><\/div><\/div><\/section><section class=\"hb-sec\" id=\"cost\"><div class=\"hb-wrap\"><h2 class=\"hb-sec-h\">Where the cost difference actually comes from<\/h2><div class=\"hb-two\"><div><h3>Flooded lead-acid<\/h3><ul><li>About 1,500 cycles with good maintenance<\/li><li>About 8 hours of work, then 16 hours to charge and cool<\/li><li>24\/7 operation typically needs three batteries per truck<\/li><li>Watering, equalising, a ventilated charging room and battery-change equipment<\/li><li>Voltage drops as it discharges; trucks slow down late in the shift<\/li><\/ul><\/div><div><h3>LiFePO4<\/h3><ul><li>Over 3,000 cycles<\/li><li>Charges in the truck at breaks; no cool-down and no swap<\/li><li>One battery per truck for multi-shift work<\/li><li>Sealed, no watering, no acid or gassing<\/li><li>Steady voltage to the end of the shift<\/li><\/ul><\/div><\/div><p class=\"hb-note\">Lithium costs more per battery, but labour, spare batteries and charging-room space usually decide total cost per shift. More: <a href=\"https:\/\/holobattery.com\/how-to-choose-the-right-forklift-battery\/\">How to Choose the Right Forklift Battery<\/a>.<\/p><\/div><\/section><section class=\"hb-sec tint\" id=\"engineering\"><div class=\"hb-wrap\"><h2 class=\"hb-sec-h\">What we engineer into a forklift pack<\/h2><dl class=\"hb-cover\"><div><dt>Cells and modules<\/dt><dd>Prismatic LiFePO4 cells in a rigid module structure, compressed and fixed against the vibration and shocks of dock plates and floor joints.<\/dd><\/div><div><dt>BMS and truck interface<\/dt><dd>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.<\/dd><\/div><div><dt>Charger<\/dt><dd>A lithium charger matched to the pack&#8217;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.<\/dd><\/div><div><dt>Connector and cabling<\/dt><dd>The same battery connector as your truck, so charging points and trucks do not change.<\/dd><\/div><div><dt>Cold stores<\/dt><dd>Heated packs with temperature-gated charging for freezer operation; see <a href=\"https:\/\/holobattery.com\/battery-charging-and-discharging-at-high-and-low-temperatures\/\">charging at low temperatures<\/a>.<\/dd><\/div><div><dt>Standards<\/dt><dd>Industrial truck batteries are commonly assessed against IEC 62619 and UL 2580, and the truck&#8217;s electrical system against EN 1175 in Europe. Which reports cover your exact design, and what your truck maker requires, is confirmed at quotation.<\/dd><\/div><\/dl><\/div><\/section><section class=\"hb-sec\"><div class=\"hb-wrap\"><h2 class=\"hb-sec-h\">Lead time and order quantity<\/h2><p class=\"hb-sub\">From a locked specification: samples in 12\u201315 working days when cells are in stock, 20\u201325 when cells must be sourced; production in 30\u201335 working days. From the first design conversation: about 4 weeks for a finalised design with no new tooling, 8\u201312 weeks for a typical custom project, 14\u201318 weeks when certification is in scope. How each phase works: <a href=\"https:\/\/holobattery.com\/custom-batteries\/\">custom battery pack development process<\/a> and <a href=\"https:\/\/holobattery.com\/battery-pack-manufacturing\/\">our manufacturing capabilities<\/a>.<\/p><div class=\"hb-tiers\"><div class=\"hb-tier\"><div class=\"bar\"><i><\/i><\/div><b>No MOQ<\/b><span>When no tooling and no custom BMS firmware are needed.<\/span><\/div><div class=\"hb-tier\"><div class=\"bar\"><i><\/i><\/div><b>100+<\/b><span>Once tooling or custom BMS firmware enters the project.<\/span><\/div><div class=\"hb-tier\"><div class=\"bar\"><i><\/i><\/div><b>300\u2013500<\/b><span>For heavily customised packs with certification.<\/span><\/div><\/div><\/div><\/section><section class=\"hb-sec tint\" id=\"faq\"><div class=\"hb-wrap\"><h2 class=\"hb-sec-h\">Forklift battery questions<\/h2><div class=\"hb-faq\"><details><summary>Can I use my existing lead-acid charger?<\/summary><div class=\"a\">Only if it can be set to a lithium profile with the right voltage and no equalisation stage. Many cannot. Send the charger model and we will tell you, or quote a matched charger.<\/div><\/details><details><summary>Will a lithium battery change my truck&#8217;s lifting capacity?<\/summary><div class=\"a\">Not if the battery meets the minimum weight on the data plate. We add ballast to the tray so it does.<\/div><\/details><details><summary>Is opportunity charging bad for a lithium forklift battery?<\/summary><div class=\"a\">No. LiFePO4 does not need full charge cycles and has no memory effect. Short top-ups at breaks are how lithium trucks are normally run.<\/div><\/details><details><summary>How long does a lithium forklift battery last?<\/summary><div class=\"a\">Over 3,000 cycles is typical for LiFePO4 when it is not charged in the cold or discharged too deep, against about 1,500 for well-maintained flooded lead-acid.<\/div><\/details><details><summary>Do you supply batteries for AGVs and tuggers too?<\/summary><div class=\"a\">Yes; see <a href=\"https:\/\/holobattery.com\/applications\/agv-mobile-robot-batteries\/\">AGV and mobile robot batteries<\/a>.<\/div><\/details><\/div><\/div><\/section><section class=\"hb-sec\"><div class=\"hb-wrap\"><h2 class=\"hb-sec-h\">Further reading<\/h2><div class=\"hb-reading\"><a href=\"https:\/\/holobattery.com\/how-to-choose-the-right-forklift-battery\/\"><b>How to Choose the Right Forklift Battery<\/b><span>Voltages, charging, safety and cost of lead-acid vs lithium.<\/span><\/a><a href=\"https:\/\/holobattery.com\/lithium-vs-lead-acid\/\"><b>Lithium vs Lead Acid<\/b><span>Chemistry differences behind the cost per cycle.<\/span><\/a><a href=\"https:\/\/holobattery.com\/what-is-deep-discharge\/\"><b>Depth of Discharge and Battery Lifespan<\/b><span>Why usable capacity differs between chemistries.<\/span><\/a><a href=\"https:\/\/holobattery.com\/battery-cycle-life\/\"><b>Battery Cycle Life<\/b><span>What determines how many shifts a pack will last.<\/span><\/a><\/div><\/div><\/section><section class=\"hb-quote\"><div class=\"hb-wrap\"><h2 class=\"hb-sec-h\">Send your forklift battery details<\/h2><p class=\"hb-sub\">An engineer replies with questions or a proposed configuration. The more of this list you can share, the faster we can quote:<\/p><ul class=\"hb-sendlist\"><li>Truck make, model and class<\/li><li>Current battery voltage, Ah and tray dimensions<\/li><li>Minimum battery weight from the data plate<\/li><li>Connector type<\/li><li>Shifts per day and break pattern<\/li><li>Charger model, or need a new charger<\/li><li>Operating temperature, including cold stores<\/li><li>Number of trucks<\/li><\/ul><a class=\"hb-btn hb-btn-primary\" style=\"margin-top:32px\" href=\"https:\/\/holobattery.com\/contact\/\">Send your forklift battery details<\/a><\/div><\/section><\/div>","protected":false},"excerpt":{"rendered":"<p>LiFePO4 forklift batteries built to your truck: lead-acid replacement sizing, counterweight ballast, charger matching and opportunity charging.<\/p>\n","protected":false},"author":1,"featured_media":0,"parent":9002,"menu_order":3,"comment_status":"closed","ping_status":"closed","template":"","meta":{"footnotes":"","_members_access_role":[],"_members_access_error":""},"class_list":["post-9004","page","type-page","status-publish"],"_links":{"self":[{"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/pages\/9004","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/pages"}],"about":[{"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/types\/page"}],"author":[{"embeddable":true,"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/comments?post=9004"}],"version-history":[{"count":0,"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/pages\/9004\/revisions"}],"up":[{"embeddable":true,"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/pages\/9002"}],"wp:attachment":[{"href":"https:\/\/holobattery.com\/wp-json\/wp\/v2\/media?parent=9004"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}