Custom Lithium Battery Packs for Forklifts
A lithium forklift battery replaces lead-acid with a pack that charges between tasks, needs no watering and holds steady voltage as it empties. Jetray builds custom LiFePO4 packs to fit your truck's battery bay, voltage and charger.
Lithium or lead-acid for forklifts
Lithium costs more at first. It saves on charging time, water, upkeep and battery swaps. Whether it pays back depends on how many shifts the truck runs.
One point to check: on many trucks the lead-acid battery is also the counterweight. A lighter lithium pack may need added weight in the case. Tell us the truck model and the weight of the present battery, and we design for it.
Common voltages
Your truck's controller and motor decide the voltage. Capacity (Ah) comes from the run time you need, and the space in the bay limits it. We confirm both before we quote.
24 V
- Typical trucks
- Pallet jacks, stackers, small trucks
36 V and 48 V
- Typical trucks
- Counterbalance trucks, reach trucks
72 V and 80 V
- Typical trucks
- Larger counterbalance trucks
What to send us
If you have no drawing, send photos with a ruler beside the bay. Enclosure design
- 01Truck brand, model and year, or the old battery's label.
- 02Voltage and capacity of the present battery.
- 03Bay dimensions, weight limit and mounting points.
- 04Connector type and cable position.
- 05The charger you use, or the charging method you want.
- 06Shifts per day and the load on the truck.
Built for forklift duty
- Cells LiFePO4, chosen for stability and many cycles. Cell selection
- Current sized to the truck's peak current, not only the average.
- BMS protection against overcharge, over-discharge, over-current, short circuit and high temperature. BMS design
- Communication CAN, UART, RS485 and Bluetooth can be set up to your requirement, so the truck or a monitor can read charge level and faults.
- Enclosure plastic or sheet metal, IP65 as our usual level and other levels on request. Sheet metal suits the knocks of a warehouse floor.
- Charger we supply a matching charger. Charger and communication
- Charge ports side or top ports for charging without removing the pack, if your workflow needs it.
Safety and documents
Forklift packs work in busy aisles, so protection and a strong case matter. UN38.3, IEC 62133 and MSDS documents are available, with transport and certification reports for the shipment. Other requirements, such as UL, depend on your market and customer. Tell us early. Quality and certification
Order size and delivery
MOQ depends on the product. Send the quantity you plan. Custom packs usually take one to two months, and items in stock ship without waiting. Custom battery pack samples are charged, and you test the sample on your truck before the batch. We ship worldwide from Shenzhen. Cost and MOQ Prototyping and samples
Options you can set
Mark what you want to discuss. Your picks go into the quote form below.
Mistakes to avoid when replacing a forklift battery
- 01
Matching only the voltage
WhyThe bay size, connector, weight and charger profile must match too. A pack with the right voltage can still fail to fit or to start the truck.
- 02
Ignoring peak current
WhyLifting a full pallet draws far more current than driving empty. Size the pack and BMS for the peak, not the average.
- 03
Forgetting the counterweight
WhyA lighter pack changes how the truck balances. Check this before the first order, not after.
- 04
Keeping the old charger
WhyA lead-acid charger does not suit LiFePO4 cells. Plan the charger with the pack.
- 05
Skipping a sample
WhyTest one pack on the real truck through a full shift before you order the batch.
From first message to delivery
- 1Send the truck model, old battery label and bay photos.
- 2We check fit, voltage and current, then reply with a cell and BMS plan and a quote.
- 3We build a charged sample, and you test it on your truck for a full shift.
- 4We adjust the case, connector or BMS settings from your test notes.
- 5Batch production, final test and shipment worldwide from Shenzhen, with transport documents.
Frequently asked questions
Usually yes, if the voltage, size, connector and charger match. Send the truck model and bay size, and we confirm on a sample.
The truck's controller decides. Common values are 24 V, 36 V, 48 V and 80 V. Check the label on your present battery.
It needs a charger set for the pack's chemistry and cell count. We supply a matching charger.
Possibly not. Many trucks use the battery as counterweight, so we design the case or add weight for it.
Yes. Short top-up charges suit LiFePO4, and the BMS sets the charge limits.
It depends on the product. Send your quantity and we confirm.
Yes, if you send a drawing or photos with a ruler. We build the case to the bay and mounting points.
Yes. Private label is supported, so the pack can carry your name and model number.
Yes. We work with truck makers, battery distributors and dealers who supply battery upgrades.
Replacing forklift batteries?
Send the truck model, voltage and bay size. We reply within 24 hours.
Your forklift lithium battery packs
Values from the tools above are already here. Add what you know and send.
Your message to an engineer
Fill what you know. Blank lines are fine.Goes straight to our sales engineers, the same as the quote form. Need to attach a drawing? Use the quote form or email it.
Replacing forklift batteries? Send the truck model, voltage and bay size.
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