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What New Or Refurbished Forklift Batteries Do You Offer?
Redway Power offers new and refurbished lithium-ion forklift batteries (24V–80V) tailored for Class I–III equipment. New options feature LiFePO4/NMC chemistries with 2,000–5,000 cycles, while refurbished units include reconditioned cells, upgraded BMS, and 1–3 year warranties. Both types support fast charging (<2hrs) and integrate with OEM systems like Crown and Toyota. 24V Lithium Forklift Battery Category
What distinguishes new from refurbished forklift batteries?
New batteries use pristine LiFePO4/NMC cells with full 5-year warranties, while refurbished packs combine graded-A recycled cells and fresh modules. Key differences include cycle counts (5,000 vs. 3,000) and price (refurbished costs 40–60% less). Both undergo ISO-certified safety testing.
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New forklift batteries deliver peak energy density (150–200 Wh/kg) and 100% Depth of Discharge (DoD), ideal for multi-shift operations. Refurbished units replace ≤20% of cells and reuse 80% of original hardware—think of it like a car engine rebuild: core components stay, but critical wear parts get upgraded. Pro Tip: Verify refurbished BMS firmware versions—outdated systems can’t handle Li-ion’s fast-charge protocols. For example, a refurbished 48V 600Ah battery often provides 90% of new capacity at half the cost, suited for seasonal warehouses.
| Feature | New Battery | Refurbished |
|---|---|---|
| Cycle Life | 5,000+ | 2,000–3,000 |
| Warranty | 5 years | 1–3 years |
| Price (48V 600Ah) | $12,000 | $5,500–$7,000 |
Which voltage options are available?
Redway stocks 24V, 36V, 48V, 72V, 80V systems covering 2,000–15,000 lb. forklifts. 24V fits walkie stackers, while 80V powers high-tonnage container handlers. Custom voltages (±10%) accommodate legacy equipment.
Voltage determines motor torque and runtime—higher volts mean fewer voltage drops under load. A 36V 400Ah battery runs ~8 hrs on electric pallet jacks, whereas 48V 800Ah supports 12-hr shifts in reach trucks. Pro Tip: Match battery voltage to controller specs—72V in a 48V system fries MOSFETs within minutes. Consider this real-world math: 48V × 800Ah = 38.4 kWh, sufficient for 12–14 hrs of 2.5-ton lifts.
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Moreover, hybrid configurations (e.g., 80V split into dual 40V modules) enable flexible compartment fitting.
Why choose lithium over lead-acid?
Lithium offers 2–3× faster charging, 70% less weight, and zero maintenance versus lead-acid. LiFePO4 handles 100% DoD daily without sulfation—ideal for refrigerated warehouses where acid batteries lose 40% capacity below 0°C.
Lead-acid requires weekly watering and 8-hour cooldowns, while lithium supports opportunity charging during breaks. Imagine fueling a truck during coffee stops versus mandatory 4-hr pit stops—lithium’s flexibility adds 20–30% uptime. Technically, LiFePO4’s flat discharge curve (48V stays 48V until 10% SOC) prevents power loss during heavy lifts. However, does lithium work in old forklifts? Yes, but retrofitting requires replacing charge ports and updating motor controllers.
| Metric | LiFePO4 | Lead-Acid |
|---|---|---|
| Cycle Life | 2,000–5,000 | 500–1,200 |
| Energy Density | 150 Wh/kg | 30 Wh/kg |
| Charge Time | 1–2 hrs | 8–10 hrs |
What’s the typical lifespan of these batteries?
New LiFePO4 lasts 8–10 years (5,000 cycles at 80% DoD), while refurbished units provide 4–6 years (2,500 cycles). Lead-acid averages 1,200 cycles but degrades 30% faster in cold environments.
Lifespan hinges on temperature management and charging habits. Keeping cells at 15–35°C via active cooling (new models) extends life by 3× versus passive systems. For example, a 48V battery in Miami without thermal management might lose 15% capacity yearly, whereas climate-controlled units degrade <5%. But what kills lithium fastest? Constant 95–100% SOC storage—maintain 30–80% for warehouse reserves. Pro Tip: Every 0.1C reduction in charge rate (e.g., 50A instead of 100A for 500Ah) doubles cycle life.
Are Redway batteries compatible with all forklifts?
They fit 70%+ of electric forklifts via adjustable mounting racks and adapter plates. Compatibility checks require model, voltage, and BMS communication type (CAN, RS485). Custom terminals solve legacy connector mismatches.
For Nissan or Clark models pre-2010, Redway provides DIN-size replacements with integrated voltage converters. Think of it as USB-C adapters for old iPhone cables—retrofitting bridges the tech gap. Warning: Counterbalance trucks need ±2% voltage tolerance—a 36V battery won’t substitute 48V without controller recalibration. Pro Tip: Snapshot your forklift’s battery compartment dimensions and terminal layout before ordering.
How do costs compare over 5 years?
New lithium’s $15,000 upfront cost beats lead-acid’s $6,000 + $18,000 in replacements/energy over 5 years. Refurbished lithium cuts initial spend by 50% while still saving $9,000 versus lead-acid.
Breakdown: A new 48V 600Ah LiFePO4 uses $1,200/year in electricity (92% efficiency), whereas lead-acid consumes $2,500/year (75% efficiency). But isn’t lithium pricier? Yes, until you factor in labor—eliminating watering saves 30 mins/day, or $4,500 in wages annually. Real-world case: A Pepsi depot saved $28,000/vehicle over 6 years by switching 20 forklifts to Redway’s refurbished 80V packs.
Redway Battery Expert Insight
FAQs
No—lithium batteries only work in electric forklifts. Combustion engines lack motor controllers and charging circuits.
Do refurbished batteries include new BMS?
Yes, all refurbished units get upgraded BMS with temperature/voltage cutoff—3X safer than lead-acid’s basic relays.
How to recycle expired batteries?
Redway offers buyback programs—we extract reusable cells and ethically recycle the rest, complying with Basel Convention.
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