What Is The 24V Lithium Battery Used For In Forklifts?
24V lithium batteries are compact, high-efficiency power sources designed for Class II/III forklifts, pallet jacks, and warehouse equipment. Using LiFePO4 chemistry, they provide rapid charging (1–2 hours), 2,000–5,000 cycles, and maintenance-free operation, ideal for multi-shift logistics. Unlike lead-acid, they maintain stable voltage under load, ensuring consistent lift speeds and reducing downtime by 30–50%.
36V 250Ah LiFePO4 Forklift Battery
Why use 24V lithium batteries instead of lead-acid in forklifts?
24V lithium batteries outperform lead-acid in energy density (120–150 Wh/kg vs. 30–50 Wh/kg), lifespan, and operational efficiency. They eliminate acid leaks, reduce charging times by 70%, and operate reliably at 95% depth of discharge (DoD).
Lead-acid batteries degrade rapidly beyond 50% DoD and require weekly watering, adding labor costs. In contrast, LiFePO4 cells deliver full capacity even in fast-cycling applications like electric pallet trucks. For example, a 24V 100Ah lithium pack can power a 2-ton forklift for 6–8 hours vs. 4–5 hours with lead-acid. Pro Tip: Install temperature sensors on Busbars—cell balancing issues often start here during high-current draws.
What forklift models typically use 24V lithium batteries?
24V lithium batteries are standard in Class III electric stackers, narrow-aisle reach trucks, and walkie pallet jacks. Brands like Toyota BT Reflex, Crown SC 5200, and Hyster P1.6DS utilize these systems for maneuverability in tight spaces.
Warehouses favor 24V systems for equipment under 3,000 lbs. capacity due to their balance between torque and energy efficiency. A typical 24V 80Ah lithium battery weighs 55 lbs.—half the mass of equivalent lead-acid—freeing up 100+ lbs. for payload. Real-world example: Jungheinrich ERS 225a reach trucks upgraded to lithium achieve 18% faster lifts and 22% longer runtime per charge. Pro Tip: Check motor controller compatibility—some older models lack voltage stabilization for lithium’s flat discharge curve.
| Equipment Type | Lead-Acid Runtime | Lithium Runtime |
|---|---|---|
| Walkie Pallet Jack | 4–5 hours | 7–8 hours |
| Electric Stacker | 5–6 hours | 9–10 hours |
48V 550Ah LiFePO4 Forklift Battery Pack
How do 24V lithium batteries handle frequent partial charging?
24V lithium batteries thrive under partial-state-of-charge (PSOC) conditions, unlike lead-acid which sulfates. LiFePO4 cells suffer no memory effect, allowing opportunity charging during breaks without capacity loss.
Advanced BMS modules actively balance cells during micro-cycles, preventing voltage drift. For instance, a forklift charged three times daily (20%, 50%, 80%) will maintain 95% capacity after 3 years. Lead-acid counterparts lose 40% capacity under similar use. Pro Tip: Use chargers with adaptive current scaling—30A for mid-shift top-ups, 80A for full recharges. Transitional phases matter: if batteries sit below 10% SoC for weeks, passive balancing becomes critical to recover cell parity.
What safety features do 24V lithium forklift batteries include?
24V lithium batteries integrate multi-layered protection: BMS-controlled overcurrent/overvoltage cutoff, ceramic separators for thermal runaway prevention, and IP67 enclosures resisting water/dust ingress.
Unlike vented lead-acid, lithium systems emit no hydrogen gas, enabling safe use in food storage or chemical plants. For example, a 24V 200Ah pack for cold storage (-20°C) uses self-heating cells that pre-warm electrolytes before discharging. Pro Tip: Monitor cell impedance quarterly—rising values (>30 mΩ) indicate aging cells needing replacement. Transitioning from theory to practice: warehouses using lithium report 60% fewer incident reports related to battery spills or fumes.
| Feature | Lead-Acid | Lithium |
|---|---|---|
| Thermal Runaway Risk | Low | Very Low (with LFP) |
| Ventilation Required | Yes | No |
Battery Expert Insight
FAQs
Only if the forklift’s motor and controller support lithium’s voltage profile—some legacy systems need retrofitting to avoid communication errors with the BMS.
How long do 24V lithium forklift batteries last?
Typically 8–10 years with daily use, 3–4x longer than lead-acid. Capacity retention stays above 80% for 2,000+ cycles when kept below 35°C.
Are 24V lithium batteries safe in cold storage?
Yes, with built-in self-heating systems. Specialized models like our 48V 630Ah Lithium Forklift Battery operate from -30°C to 60°C, perfect for freezer warehouses.