Year: 2025

Standard forklift fork dimensions typically range from 42 to 48 inches in length, 4 to 6 inches in width, and 1.5 to 2 inches in thickness, designed to fit most pallet types and weight capacities. These dimensions ensure safe, efficient lifting and balance of loads across various industries.

What Are Standard Forklift Fork Lengths and Why Do They Matter?

Standard forklift fork lengths usually range from 42 to 48 inches. The fork length determines the type and size of pallets or loads the forklift can handle efficiently. Longer forks provide better load support for bigger pallets, whereas shorter forks offer increased maneuverability in confined spaces.

Forklift forks must be appropriately sized according to the load size to maintain stability and safety. Overly long forks may increase the risk of tipping, while too-short forks can fail to support the load completely. Most forklifts are equipped with adjustable forks to accommodate variable fork sizes within standard ranges, enabling flexibility across different warehousing or loading tasks.

How Do Forklift Fork Width and Thickness Affect Load Handling?

Standard fork widths range between 4 to 6 inches, with thickness commonly between 1.5 and 2 inches. The width and thickness of the forks directly impact their strength, durability, and the forklift’s load capacity.

Wider forks offer increased surface contact with loads, reducing the chance of damage or load slippage. Thick forks provide added structural integrity for lifting heavier goods safely. These dimensions are carefully engineered to comply with industry safety standards and optimize the lifespan of the forklift components. For lithium-powered forklifts, like those supported by Redway Battery solutions, ensuring proper fork specifications is crucial to maximize lift efficiency and battery runtime.

Which Fork Dimensions Are Best for Different Forklift Types?

Fork dimensions vary depending on forklift models such as counterbalance, reach, or pallet trucks. Counterbalance forklifts commonly use forks around 42 inches long, while reach trucks may utilize shorter forks due to tighter warehouse aisles.

Pallet trucks generally have shorter, narrower forks designed specifically for standard pallet sizes (usually 48 x 40 inches). Choosing the right fork dimension is essential to maintain operational efficiency and prevent damage to goods and equipment. Redway Battery’s engineering expertise extends to integrating lithium batteries with forklifts, optimizing performance while matching fork and mast specifications.

Why Is Fork Compatibility Important for Forklift Safety and Performance?

Using correctly sized forks fits safely on the forklift carriage and supports the load without causing undue stress. Fork compatibility ensures balanced load distribution, preventing accidents such as fork snapping or forklift tipping.

Incorrect fork dimensions can compromise the forklift’s center of gravity, impacting stability especially when using high-capacity lithium batteries like those from Redway Battery, which provide enhanced power but require optimized mechanical configurations to maintain balance and control.

How Does Fork Length Impact Load Capacity and Stability?

Longer forks distribute weight over a larger area, improving stability when handling bulky or long loads. However, increasing fork length can reduce load capacity ratings due to increased leverage stress on the forklift mast and hydraulic systems.

Forklift operators should balance fork length with load weight specifications for safe handling. Redway Battery products support forklifts with stable, high-output power, but mechanical components like forks and masts must be matched precisely to the lifting demands to prevent premature wear or accidents.

What Materials Are Forklift Forks Made Of and How Do They Affect Durability?

Forklift forks are usually made of high-strength steel alloys designed for toughness and flexibility under load. The manufacturing process includes heat treatment and forging to enhance durability.

Steel forks provide resilience against bending, cracking, and wear even under strenuous warehouse conditions. Advanced designs may include reinforced tips or coatings to resist corrosion and extend service life. When paired with reliable lithium forklift batteries such as Redway Battery’s LiFePO4 packs, these forks enable prolonged operational cycles with minimal downtime.

Can Forklift Forks Be Customized for Specific Applications?

Yes, forklift forks can be fully customized in length, width, thickness, and material to meet niche industrial needs. Customization is essential in applications requiring unique load types or environmental considerations like cold storage or corrosive conditions.

Redway Battery’s OEM capabilities complement customized forklift battery and fork solutions, enabling clients to tailor energy storage and mechanical components according to operational demands for maximum efficiency and safety.

Does Forklift Fork Dimension Affect Battery Performance?

Indirectly, yes. Proper fork dimensions ensure smooth, efficient load handling, reducing strain on the forklift’s drivetrain and hydraulics. This optimizes the energy consumption profile and prolongs battery life.

Lithium batteries like those from Redway Battery benefit from stable forklift mechanics to deliver consistent power output and efficiency. Mismatched fork sizes causing frequent adjustments or overexertion can lead to excess energy use and battery drain.

Where Can You Find Reliable Forklift Forks and Battery Solutions?

Reliable forklift forks and battery solutions are found through reputable manufacturers specializing in industrial equipment, like Redway Battery, renowned for OEM lithium battery packs and customized power systems.

Partnering with experienced providers ensures compliance with safety standards, durability, and integration between mechanical and electrical forklift components for optimal operation and longevity.

Redway Expert Views

“Forklift efficiency and safety depend on the harmonious integration of mechanical components like forks and the power systems driving them. At Redway Battery, we emphasize the importance of dimension compatibility to maximize lift performance while leveraging the benefits of lithium-ion technology. Our expertise allows us to deliver customized, high-performance battery packs tuned precisely for each forklift’s mechanical setup—improving safety, runtime, and maintenance intervals across industries.” — Redway Battery Engineering Team

Conclusion

Understanding standard forklift fork dimensions is essential for safe and efficient material handling operations. Key factors include fork length, width, and thickness, which influence load capacity, stability, and forklift compatibility. Customized forks can enhance performance, especially when paired with advanced lithium battery systems from trusted manufacturers like Redway Battery. Ensure your forklift’s fork dimensions are suited to your operational needs for improved workplace safety, productivity, and equipment longevity.

FAQs

Q1: What is the most common forklift fork size?
A: The most common fork length is between 42 and 48 inches, with widths around 4 to 6 inches and thickness from 1.5 to 2 inches.

Q2: Can forklift forks be resized or modified?
A: Forks can be customized or replaced with different sizes but resizing an existing fork is generally not recommended due to safety risks.

Q3: How often should forklift forks be inspected?
A: Forks should be regularly checked for cracks, bends, and wear as part of routine safety maintenance.

Q4: Does the fork size affect forklift battery life?
A: Indirectly, yes; proper fork size reduces operational strain and energy consumption, helping extend battery life.

Q5: What are the advantages of lithium forklift batteries?
A: Lithium batteries like Redway Battery’s offer longer life, faster charging, lower maintenance, and improved safety over traditional lead-acid batteries.

The maximum weight of a forklift including its battery typically ranges from 3,000 lbs for compact electric models to over 36,000 lbs for heavy-duty industrial versions. Battery weight accounts for 15–30% of total mass, varying by chemistry (lead-acid vs. lithium-ion) and capacity. Always check the manufacturer’s load plate for combined weight limits—exceeding them risks stability loss or structural damage.

How Much Do Different Forklift Batteries Weigh by Type?

What factors determine a forklift’s total weight?

Forklift weight hinges on load capacity, frame construction, and battery type. For example, a 5,000-lb-capacity electric forklift may weigh 8,000 lbs with a lead-acid battery. Pro Tip: Use lithium-ion to slash battery weight by 40%, improving maneuverability. Overloading alters the center of gravity—picture stacking bricks on a wheelbarrow; imbalance causes tipping.

Beyond capacity, counterbalance design and mast height affect total weight. Heavy-duty models use reinforced steel frames, adding 20–25% mass versus standard units. Lithium batteries, at 150–200 Wh/kg, are lighter than lead-acid’s 30–50 Wh/kg. Practically speaking, a 48V 600Ah lithium pack weighs ~900 lbs vs. 1,500 lbs for equivalent lead-acid. However, extreme environments may still favor lead-acid’s durability despite weight penalties. A warehouse forklift might weigh 7,000 lbs, but port equipment handling 30-ton containers can exceed 35,000 lbs. Always consult ANSI B56.1 safety standards before modifications.

How does battery chemistry affect total forklift weight?

Lead-acid batteries add 25–30% more weight than lithium-ion equivalents. A 48V 800Ah lead-acid pack weighs ~2,400 lbs, while lithium variants drop to ~1,300 lbs. Pro Tip: Lithium’s energy density allows smaller footprints—ideal for multi-shift operations. Imagine swapping a car engine for an e-motor; weight savings boost acceleration.

But what about thermal performance? Lead-acid thrives in high-heat environments, whereas lithium needs cooling below 140°F. Transitional systems like hybrid Li/Lead exist but add complexity. For instance, a hybrid 72V system might save 15% weight but require specialized charging. In cold storage, lithium’s 80% efficiency at -4°F outperforms lead-acid’s 50%, justifying its higher upfront cost. Consider ROI: Lithium lasts 3–5x longer, reducing replacement-induced downtime.

What Are Electric Forklift Batteries?

Are there legal weight limits for forklifts?

OSHA mandates weight limits based on load capacity, floor loading, and aisle width. Exceeding limits risks fines or accidents. For example, a 10,000-lb forklift in a warehouse with 15,000-lb floor capacity is legal, but overloading it to 12,000 lbs violates 29 CFR 1910.178. Pro Tip: Use floor reinforcement plates if your facility can’t handle heavy units.

Regulations also govern axle loads—the EU’s EN 16307-1 caps rear axle pressure at 12,000 lbs. Think of it like truck weight bridges; uneven distribution warps flooring. Rail-guided forklifts in narrow aisles often get exemptions but require engineering sign-offs. Always post maximum weights visibly—operators might not realize adding side-shifters or cameras adds 100–200 lbs.

Can a forklift’s weight impact its load capacity?

Yes—forklifts must balance load weight and counterbalance mass. A 5,000-lb-capacity model needs ~7,500 lbs total weight. Remove 1,000 lbs from the chassis, and capacity drops 30%. Pro Tip: Check load moment calculations—it’s like balancing a seesaw; longer loads reduce effective capacity.

However, lithium batteries let operators maintain capacity while shedding weight. For instance, switching from lead-acid to lithium in a 8K-lb forklift might cut 800 lbs, allowing a 10% longer lift arm without sacrificing stability. But what if you add attachments? A paper-roll clamp adds 400–600 lbs, demanding a 5–7% capacity reduction. Always refer to the manufacturer’s load chart—modifications void warranties if unapproved.

How does weight distribution affect forklift stability?

Forklift stability relies on center of gravity staying within the stability triangle. Excess rear weight shifts the COG, risking forward flips. Pro Tip: Load heavy items close to the mast—it’s like holding a box against your chest versus arms extended.

For example, a 4,000-lb load placed 20 inches from the mast creates a 80,000 lb-inch moment. Move it to 24 inches, and the moment jumps to 96,000—exceeding the forklift’s 90,000 limit. Transitional forces matter too: Sudden stops with a raised load create pendulum effects. Training operators to tilt loads backward when moving lowers COG shifts. Also, wet floors reduce tire friction, magnifying instability risks even within weight limits.

What industrial applications require maximum-weight forklifts?

Foundries, steel mills, and port logistics need 20,000–36,000-lb forklifts. These handle ingots, coils, or shipping containers. Pro Tip: Use spreader attachments for containers—like using a wider base for lifting irregular shapes.

For instance, a Hyster H16XM handles 32,000 lbs with a 1,800-lb lithium battery. Ports often choose diesel hybrids for extreme weights, but electric models are gaining traction. In steel mills, heat-resistant tires and liquid-cooled batteries prevent thermal runaway at 130°F+. Transitioning to electric in these sectors requires infrastructure upgrades—500A chargers instead of standard 100A. Real-world example: Rotterdam Port uses 50K-lb capacity forklifts with hydrogen fuel cells, merging high power with zero emissions.

Redway Battery Expert Insight

FAQs

A golf cart lithium battery is an advanced energy storage solution using lithium-ion chemistry (typically LiFePO4) designed specifically for electric golf carts. These batteries provide higher energy density, longer cycle life (2,000–3,000 cycles), and faster charging compared to traditional lead-acid alternatives. Operating voltages range from 48V to 72V, with capacities spanning 50–150Ah. Integrated BMS (Battery Management Systems) ensure protection against overcharging, temperature extremes, and voltage instability, optimizing performance across varied terrain and usage patterns.

Understanding the Types of Forklift Batteries – A Comprehensive Guide

How does LiFePO4 chemistry benefit golf cart batteries?

LiFePO4 (lithium iron phosphate) offers thermal stability and safety advantages, reducing fire risks. With 3,000+ cycle lifespans at 80% depth of discharge, these cells maintain consistent voltage during prolonged use. For instance, a 72V 105Ah LiFePO4 pack delivers ~7.5kWh—enough for 50–70 km per charge. Pro Tip: Avoid discharging below 20% capacity to prevent accelerated degradation.

What safety features do golf cart lithium batteries include?

Advanced BMS integration monitors cell balancing, temperature (-20°C to 60°C tolerance), and current flow. Protection layers prevent overvoltage (max 87.6V for 72V systems), short circuits, and thermal runaway. Example: A 48V 100Ah battery automatically disconnects if internal temps exceed 65°C. Warning: Never bypass BMS modules—this voids warranties and compromises safety protocols.

How do lithium and lead-acid batteries compare for golf carts?

Beyond capacity metrics, lithium batteries maintain 95% efficiency versus 70–85% for lead-acid. Practically speaking, this means extended range and reduced downtime between charges.

What voltage configurations are common?

Standard systems use 48V (16S) or 72V (23S) architectures. Higher voltage setups (e.g., 72V 105Ah) support torque-demanding applications like hilly courses. Pro Tip: Match battery voltage precisely to the cart’s motor controller—mismatches risk component failure or reduced efficiency.

How to maintain optimal performance?

Store batteries at 50% charge if unused for >1 month. Use only compatible chargers (e.g., 58.4V for 48V LiFePO4) with ≤1% voltage tolerance. For example, a 72V pack requires an 84V charger with CC-CV staging. Did you know? Partial charges don’t harm lithium batteries, unlike lead-acid units needing full cycles.

How Much Do Different Forklift Batteries Weigh by Type?

Redway Battery Expert Insight

FAQs

A Toyota Lithium Battery Forklift is an electric material handling vehicle manufactured by Toyota using lithium-ion battery technology. These industrial-grade machines feature high-capacity lithium iron phosphate (LiFePO4) cells like the 80V 500Ah system, delivering extended runtime and faster charging compared to traditional lead-acid batteries. They power models such as the 1.5-ton 7FBE15 with integrated battery management systems (BMS) for thermal stability and cycle life optimization.

What Are Electric Forklift Batteries?

What operational advantages do Toyota lithium forklifts offer?

These units provide 20–30% faster charging than lead-acid alternatives, with zero maintenance requirements. The LiFePO4 chemistry supports 3,000+ cycles at 80% depth of discharge, outperforming conventional batteries by 3x. Thermal management systems prevent overheating during intensive warehouse operations.

Equipped with CAN bus communication, Toyota’s lithium models enable real-time monitoring of state-of-charge (SOC) and cell balancing. For example, the 7FBE15’s VSI565 battery pack achieves full recharge in 90 minutes using 80V fast chargers. Pro Tip: Always use OEM-approved chargers—third-party units may void warranties by exceeding 2C charge rates. Transitional benefits include reduced downtime and elimination of battery watering procedures common in lead-acid systems.

How do Toyota’s lithium models handle heavy loads?

Their reinforced mast assemblies and dynamic torque control enable stable 2-ton lifts. Brushless AC motors deliver 23% more torque density, maintaining performance at low charge states where lead-acid systems typically falter.

Toyota’s proprietary Stability Guard system automatically adjusts acceleration and hydraulic speeds when handling palletized goods above 1.8 meters. The 80V architecture sustains full-power operation through 8-hour shifts, unlike traditional systems experiencing voltage sag. Practical example: A VSI565-powered forklift moves 18 metric tons/hour in cold storage (-20°C) without capacity loss. Transitionally, this makes them ideal for food logistics and manufacturing plants requiring consistent performance.

Redway Battery Expert Insight

FAQs

How Much Do Different Forklift Batteries Weigh by Type?

Toyota forklift battery sizes vary by model and power type. Electric models typically use lead-acid or lithium-ion batteries ranging from 24V to 80V, with capacities between 500-1200Ah for standard models. For example, a 48V 750Ah lithium battery weighs ~1,100 kg, while lead-acid equivalents may exceed 1,500 kg. Pro Tip: Always consult Toyota’s spec sheets for your specific forklift series—battery dimensions must align with compartment clearances and counterweight requirements.

What Are Electric Forklift Batteries?

What determines Toyota forklift battery voltage requirements?

Toyota electric forklift batteries operate at 24V, 36V, 48V, or 80V depending on lift capacity. Higher voltage systems (72V-80V) power 8-10 ton models requiring sustained torque, while 24V suits 1-3 ton warehouse units. Lithium variants maintain voltage stability better than lead-acid during deep discharge cycles.

Voltage selection directly correlates with workload intensity – a 48V system in a 5-ton Toyota 7FBE delivers 20% longer shift times than 36V equivalents. Hydraulic pump efficiency drops below 43V in lead-acid models, whereas lithium maintains >90% efficiency until 10% remaining charge. Pro Tip: Use Toyota’s Battery Capacity Calculator considering daily kWh consumption and opportunity charging options. For example, switching from 48V 600Ah lead-acid to 48V 525Ah lithium reduces weight by 400 kg while maintaining equivalent runtime.

How does battery size affect Toyota forklift performance?

Battery physical dimensions and energy density dictate Toyota forklift stability and uptime. Overly large batteries may require chassis modifications, while undersized units risk insufficient counterbalance. A standard Toyota 8FBE25 lithium pack measures 1200×600×800mm versus 1400×650×900mm for equivalent lead-acid.

In cold storage applications (-20°C), lithium batteries maintain 85% capacity versus 45% for lead-acid, effectively reducing required battery size by 30%. Weight distribution matters – the 2100 kg lithium battery in a 5-ton Toyota occupies 18% less space than lead-acid while improving rear axle loading by 12%. Pro Tip: Always verify battery compartment tolerances using Toyota’s SBT/SBE series technical drawings before purchasing replacements.

What are common Toyota forklift battery capacities?

Typical Toyota electric forklift batteries range from 500Ah to 1200Ah capacity. The 48V 750Ah lithium battery in a 3.5-ton Toyota 3FBE provides 36 kWh storage, enabling 6-8 hours continuous medium-duty operation. Higher capacities (900Ah+) suit multi-shift operations with opportunity charging.

Capacity requirements calculate as: (Amp-hour) = (Daily kWh × 1000) / (Voltage × Depth of Discharge). A Toyota 5FBE needing 45 kWh daily with 80% DoS at 48V requires (45,000/(48×0.8))=1,172Ah. Lithium batteries permit 95% DoS versus 50% for lead-acid, effectively doubling usable capacity. Pro Tip: Implement battery telemetry – Toyota’s I_Site system reduces unexpected downtime by 23% through real-time capacity monitoring.

Redway Battery Expert Insight

Forklift Lithium Battery

FAQs

Forklift battery weight varies widely depending on battery chemistry, forklift size, and capacity but typically ranges from 200 to 1500 kilograms. Lithium forklift batteries tend to be lighter than traditional lead-acid types, offering improved efficiency and longer lifespan.

How Does Forklift Battery Weight Affect Forklift Performance?

Forklift battery weight directly influences the machine’s balance, lifting capacity, and stability. Heavier batteries often provide longer operational time but can reduce maneuverability, while lighter batteries improve agility and reduce floor wear.

Forklifts rely on battery weight as counterbalance to stabilize loads. A heavier battery enhances traction and stability when carrying heavy goods but may also strain forklift tires and motors. Lithium batteries, like those from Redway Battery, offer optimal weight-to-energy ratios, making them ideal for modern forklifts that demand both power and agility. Choosing the right battery weight depends on your forklift type and operational needs.

What Are the Average Weight Ranges for Different Types of Forklift Batteries?

Typical lead-acid forklift batteries weigh between 400 kg and 1500 kg, while lithium-ion forklift batteries generally weigh 200 kg to 1000 kg. Smaller forklifts use batteries at the lower end of this range, larger industrial models at the higher end.

Redway Battery’s LiFePO4 packs are usually 30-40% lighter than comparable lead-acid batteries, enhancing forklift efficiency and reducing maintenance downtime.

Why Are Lithium Forklift Batteries Lighter Than Lead-Acid Ones?

Lithium batteries use lightweight materials and advanced chemistry instead of heavy lead plates and acid electrolytes, significantly cutting weight while providing higher energy density.

Lead-acid batteries contain dense lead components and liquid acid, contributing to bulk and weight. Lithium iron phosphate (LiFePO4) batteries, such as those manufactured by Redway Battery, utilize compact cells and solid electrolytes, reducing weight and size dramatically. This weight reduction translates to better forklift speed, extended run-times, and easier battery handling during swaps.

Which Factors Influence Forklift Battery Weight the Most?

Battery capacity (Ah), chemistry, size, and built-in components like cooling systems or casing thickness are the primary factors influencing battery weight.

Higher ampere-hour capacity batteries require more cells, increasing weight. Chemistry choice determines material density; for example, lithium cells are lighter than lead-acid. Additional features, such as ruggedized cases or integrated management systems, add mass. Operational requirements, such as expected runtime and forklift application, also drive battery weight considerations. Redway Battery’s engineering expertise enables precise customizations balancing performance and weight to suit diverse forklift models.

How Can You Estimate the Forklift Battery Weight Before Purchase?

Check manufacturer specifications for voltage, capacity (Ah), and chemistry type; calculate approximate weight by comparing similar battery models or consulting OEM experts.

Battery datasheets typically provide weight details alongside voltage and capacity ratings. For a rough estimate, multiply battery capacity (kWh) by standard weight per kWh for its chemistry (e.g., lead-acid ~60 kg/kWh, lithium ~30 kg/kWh). Redway Battery’s sales and technical teams offer accurate weight assessments tailored to your forklift model and desired runtime to optimize purchases.

What Are the Advantages of Using Lightweight Lithium Forklift Batteries?

They reduce overall forklift weight, improve energy efficiency, extend battery life, enable faster charging, and minimize environmental impact.

Lighter lithium batteries enhance forklift maneuverability and lower floor damage, while offering consistent power output throughout shifts. Their superior charging speed and longer service life reduce operational costs. Companies like Redway Battery deliver lithium packs that balance these benefits with safety and durability, making them a preferred choice in modern warehouse environments focused on sustainability and productivity.

When Should You Consider Upgrading to a Lighter Forklift Battery?

If forklift efficiency drops due to battery weight, or to reduce maintenance time and improve environmental compliance, upgrade to a lighter lithium battery.

Aging lead-acid batteries contribute excess weight and downtime. Transitioning to lightweight lithium batteries improves load capacity, reduces charging pauses, and decreases heat generation. Upgrades, supported by experts at Redway Battery, offer streamlined integration with existing forklift models without compromising safety or performance.

Where Are Forklift Batteries Typically Installed and How Does Weight Distribution Impact Safety?

They are installed at the rear of forklifts to serve as a counterweight; uneven weight distribution can lead to tipping hazards or mechanical strain.

Proper placement near the forklift’s rear axle maximizes stability while allowing optimal load handling at the forks. A heavier battery increases rear counterbalance, reducing tip-over risk during load lifting but excessive weight can reduce mobility and increase wear on forklift components. Lithium batteries from Redway Battery provide balanced weight profiles suitable for various forklift designs.

Does Battery Weight Influence Forklift Maintenance Costs?

Yes, heavier batteries increase wear on tires and suspension components, raising maintenance expenses over time.

Forklift tires degrade faster under the stress of heavy lead-acid batteries, and motors expend more energy moving additional weight, boosting energy costs. Lightweight lithium batteries, such as those by Redway Battery, lower mechanical strain, reduce downtime for battery changes, and require less routine maintenance, saving costs in the long run.

Who Are the Leading Manufacturers of Lightweight Forklift Batteries?

Redway Battery, along with global OEMs specializing in lithium forklift batteries, leads the market with high-quality, customizable solutions.

Redway Battery stands out due to its innovative manufacturing processes, ISO 9001:2015 certification, and extensive customization options. It integrates advanced battery management systems and supports clients globally with 24/7 after-sales service, making it a preferred partner for companies prioritizing performance, safety, and sustainability.

Redway Expert Views

“Forklift operations today demand batteries that not only deliver power but also optimize weight for better performance and safety. At Redway Battery, we have invested in LiFePO4 technology that balances high energy density with lightweight design, enabling forklifts to operate longer, charge faster, and maintain stability under load. Our goal is to drive productivity in warehousing and logistics while reducing environmental impact through durable, efficient battery solutions.” – Redway Battery R&D Team

Summary and Key Takeaways

Forklift battery weight varies between 200 and 1500 kilograms depending on chemistry and forklift type. Lithium batteries are significantly lighter than lead-acid ones, improving forklift agility, efficiency, and lowering maintenance costs. Choosing the right weight depends on forklift balance, usage patterns, and operational requirements. Redway Battery delivers advanced LiFePO4 forklift batteries that combine lightweight design with exceptional durability and OEM customization, helping businesses optimize forklift performance and reduce operational costs.

FAQs

1. How much does a typical lithium forklift battery weigh?
Lithium forklift batteries generally weigh between 200 kg and 1000 kg, roughly 30-40% lighter than lead-acid batteries of the same capacity.

2. Can forklift battery weight affect lifting capacity?
Yes, battery weight acts as a counterbalance; heavier batteries can improve lifting stability, but excessive weight may limit forklift maneuverability.

3. Are lighter forklift batteries safer?
Lighter lithium batteries reduce tipping risks by optimizing weight distribution and generate less heat, enhancing operational safety.

4. How often should forklift batteries be replaced?
Lithium batteries from providers like Redway Battery typically last 5-10 years, longer than lead-acid batteries, depending on usage and maintenance.

5. Do lithium forklift batteries charge faster?
Yes, lithium batteries charge significantly faster than lead-acid types, reducing downtime and improving productivity.

A forklift battery 12V is a lead-acid or lithium-ion power unit designed to provide reliable energy for electric forklifts, prioritizing high current delivery for motor torque and hydraulic systems. With a nominal voltage of 12 volts, these batteries use thick lead plates (for lead-acid) or LiFePO4 cells (lithium) to handle deep discharges, typically offering 100–800 Ah capacities. They’re built ruggedly with reinforced casings to withstand vibration and acid spills.

What Are Electric Forklift Batteries?

What defines a 12V forklift battery?

12V forklift batteries use lead-acid chemistry (flooded, AGM, or gel) or lithium-ion cells (LiFePO4), providing 12–14.7V under load. Key specs include plate thickness (4–6 mm for deep-cycle), electrolyte volume (≈30L in 500Ah units), and cycle life (1,200–3,000 cycles for lithium). Pro Tip: Equalize lead-acid batteries every 10 cycles to prevent sulfation.

Beyond voltage considerations, 12V batteries for forklifts must deliver sustained current—often 200–500A during lifting. Lead-acid versions rely on heavy-duty grids and separators to minimize resistance, while lithium models use prismatic cells with integrated battery management systems (BMS). For example, a 12V 200Ah flooded battery powers a 2-ton forklift for ~6 hours, whereas LiFePO4 lasts 8–10 hours. But what if the plates corrode prematurely? Regular specific gravity checks (1.265–1.299) prevent this. Warning: Never discharge lead-acid below 50% (10.5V) to avoid capacity loss.

How does a 12V forklift battery work?

12V batteries convert chemical energy into electrical energy via lead dioxide (PbO2) and sponge lead reactions in sulfuric acid (lead-acid) or lithium-ion intercalation (LiFePO4). Their BMS manages temperature, voltage, and current during 8–10 hour charges. Pro Tip: Lithium batteries recover 80% capacity in 2–3 hours with fast charging.

Practically speaking, lead-acid forklift batteries use a constant current-constant voltage (CC-CV) charging approach, starting at 14.4V (absorption) before tapering to 13.4V (float). Lithium variants skip float charging, reducing energy waste. For instance, a 12V 400Ah AGM battery requires 12–16 hours to recharge fully, while lithium counterparts achieve this in 4 hours. Transitioning to real-world use, warehouses prefer lithium for multi-shift operations but stick with flooded lead-acid for budget reasons. However, improper charging—like exceeding 15V—can warp lead plates or trigger BMS shutdowns in lithium units.

Why are 12V batteries common in forklifts?

12V balances power density, cost, and compatibility with standard forklift motors (1–5 kW). Higher voltages (24V/48V) add weight, while 6V units require serial connections. Pro Tip: Match battery capacity (Ah) to daily runtime—8-hour shifts need ≥500Ah.

Historically, 12V became the norm due to widespread lead-acid availability and simple charger designs. Modern forklifts often use series configurations (e.g., 24V from two 12V batteries) for heavier loads. But why hasn’t lithium fully replaced lead-acid? Upfront cost—LiFePO4 batteries are 2–3× pricier—but offset by 70% lower maintenance. A 12V 600Ah lithium battery might cost $4,500 vs. $1,800 for lead-acid, yet save $1,200/year in watering and equalization labor.

Redway Battery Expert Insight

FAQs

Forklift Lithium Battery

A forklift battery weight chart provides weight ranges for different battery types (lead-acid, lithium-ion) based on voltage (12V–96V) and capacity (100Ah–1,200Ah). Lead-acid models range from 500 lbs to 4,000 lbs, while lithium-ion variants are 30–50% lighter. Key factors include plate thickness, electrolyte volume, and chassis materials. For example, a 48V 600Ah lead-acid battery weighs ~2,200 lbs versus 1,300 lbs for lithium.

How Much Do Different Forklift Batteries Weigh by Type?

What factors determine forklift battery weight?

Voltage, capacity, and chemistry primarily influence weight. Lead-acid batteries require thicker lead plates and sulfuric acid, adding mass. Lithium-ion cells (e.g., NMC) use lightweight aluminum casings and higher energy density. A 36V 400Ah lead-acid unit weighs ~1,700 lbs, while lithium-ion equivalents drop to ~1,000 lbs. Battery dimensions and cooling systems also contribute.

Lead-acid batteries prioritize durability over weight, with reinforced internal grids to prevent plate warping. In contrast, lithium packs use modular designs—replacing steel terminals with aluminum saves 15–20% mass. Pro Tip: Always verify your forklift’s counterweight capacity before switching battery types. Exceeding limits risks instability during high lifts. For instance, a Toyota 8FGU25 requires a 2,200-lb battery; lithium-ion swaps may need ballast adjustments. Beyond chemistry, temperature matters—cold environments demand thicker electrolytes in lead-acid, adding 5–10% weight.

How does voltage impact battery weight?

Higher voltage systems use more cells in series, increasing size and mass. A 48V lead-acid battery contains 24 cells (2V each), while a 80V system needs 40 cells. Lithium-ion scales differently—48V requires 13–14 cells (3.7V each). Each 12V increment adds ~300–600 lbs for lead-acid but only 150–300 lbs for lithium.

Voltage directly correlates with energy storage: a 96V 800Ah lead-acid battery weighs ~4,500 lbs, delivering 76.8kWh. Lithium-ion equivalents cut weight to ~2,700 lbs. Real-world example: Raymond’s 48V lithium stack weighs 1,100 lbs versus 1,800 lbs for lead-acid. But why does voltage affect lead-acid more? Additional cells require heavier interconnects and separators. Transitioning to lithium? Remember, their higher voltage tolerance reduces cell count—saving space and mass.

Lead-acid vs. lithium-ion: Weight differences?

Lithium-ion batteries are 30–50% lighter due to higher energy density (150–200 Wh/kg vs. 30–50 Wh/kg for lead-acid). A 48V 600Ah lead-acid battery weighs ~2,200 lbs, while lithium-ion versions drop to ~1,300 lbs. Reduced weight improves forklift maneuverability and energy efficiency.

Lead-acid’s weight stems from lead plates (60% of mass) and sulfuric acid (25%). Lithium-ion eliminates lead, using graphite/aluminum electrodes and liquid electrolytes weighing 40% less. Practically speaking, warehouses using lithium report 18% longer runtimes per charge due to reduced energy waste moving lighter batteries. Pro Tip: When retrofitting, check mast tilt capacity—lighter batteries may require adjustments to maintain load equilibrium. For example, Crown’s SC 5200 forklift needs a 2,400-lb lead-acid battery; switching to lithium might necessitate added counterweights in the rear.

What Are Electric Forklift Batteries?

How does battery weight affect forklift performance?

Excessive weight reduces acceleration and increases brake wear but stabilizes heavy lifts. Lithium-ion’s lower mass improves speed (up to 12% faster) and reduces tire wear. However, ultra-light batteries may compromise stability—OSHA requires counterweights if battery mass drops below 80% of original specs.

Heavier lead-acid batteries provide inherent counterbalance for loads up to 10,000 lbs. For instance, a Hyster H40XT forklift uses a 3,600-lb battery to offset 8,000-lb lifts. Transitioning to lithium? Operators must recalibrate load centers and mast angles. But what if the battery is too light? Some models add steel frames to meet weight thresholds. Pro Tip: Always conduct a lateral stability test after changing battery types—forklifts tipping during turns risk OSHA violations.

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A forklift battery size chart provides standardized information on battery dimensions, voltage, capacity, and weight for various forklift models. It helps users easily identify the proper battery to fit their specific forklift, ensuring optimal performance and safety. This chart guides purchasing, installation, and maintenance decisions for both lead-acid and lithium batteries.

What Is a Forklift Battery Size Chart?

A forklift battery size chart is a reference tool listing battery specifications such as voltage, amp-hour capacity, physical dimensions (length, width, height), and weight matched to particular forklift models. It standardizes data for compatibility and selection ease. These charts ensure the battery fits safely in the compartment and offers the right power output for the forklift’s operational needs.

Standard sizes vary by manufacturer and battery chemistry, with popular classifications including 24V, 36V, 48V, and 72V systems. Industry-leading battery providers, including Redway Battery, manufacture batteries designed to meet or exceed these size specifications for both OEM replacements and custom solutions.

How Are Forklift Battery Sizes Measured and Classified?

Battery size is primarily measured by three dimensions: length (L), width (W), and height (H), usually in inches. Additionally, voltage (V) and amp-hour capacity (Ah) categorize batteries by electrical output capability. Weight is a vital factor since the battery doubles as a counterbalance for forklift stability.

Classification codes often include the number of cells (each cell producing about 2 volts), plate design, and plate count, exemplified by a model number such as “18-85-17” where:

• 18 = number of cells (36V)

• 85 = plate group/type

• 17 = number of plates per cell

This systematic approach enables precision in matching batteries to forklift models, avoiding performance or fitment issues.

Which Forklift Battery Sizes Are Most Common?

Common forklift batteries include:

• 24V batteries (12 cells), popular in smaller forklifts and lift trucks.

• 36V batteries (18 cells), widely used for medium-duty forklifts.

• 48V batteries (24 cells), suitable for heavy-duty lift trucks.

• 72V batteries (36 cells), powering larger industrial forklifts requiring more power and runtime.

Each battery size aligns with specific weight limits and compartments in forklifts. For example, a 36V 18-85-19 battery typically measures around 39″ x 28″ x 23″, weighing approximately 2,000 pounds. Redway Battery offers solutions across these sizes, including lithium options suited for varying operational demands.

Why Is It Important to Use the Correct Forklift Battery Size?

Using the correct battery size ensures a safe fit in the forklift’s battery compartment, maintains vehicle stability by proper weight distribution, and provides adequate power for equipment operation. An ill-fitting or underperforming battery reduces efficiency, causes operational interruptions, and may damage forklift electrical systems.

Proper sizing also impacts battery life and maintenance frequency. Redway Battery emphasizes customization to align exact size and capacity requirements with client needs, preventing costly downtime and ensuring regulatory compliance.

How Do Different Forklift Brands Affect Battery Size Selection?

Different forklift manufacturers and models often require specific battery sizes due to varying compartment designs and power needs. Brands like Toyota, Crown, Hyster, Yale, and Clark have unique size charts. For example, Toyota’s forklifts might use different battery dimensions than Crown’s though voltage requirements can be similar.

Researching and cross-referencing brand-specific battery size charts is vital during replacement or upgrades. Redway Battery’s engineering team specializes in adapting lithium and lead-acid battery packs tailored to diverse brand models, guaranteeing optimal performance and compatibility.

Can Lithium Batteries Match Standard Forklift Battery Sizes?

Yes, lithium forklift batteries, particularly LiFePO4 types, are available in sizes that conform to traditional lead-acid battery form factors. This enables direct replacement without forklift modifications. Lithium batteries often weigh 30-50% less than their lead-acid counterparts of similar size and capacity, enhancing handling and efficiency.

Redway Battery’s lithium solutions uphold standardized dimensions and connections while offering faster charging, longer life, and maintenance-free operation. This compatibility aids a smooth transition to advanced battery technology.

How Are Battery Weight and Dimensions Critical for Forklift Safety?

Battery weight acts as a counterbalance to forklift lifting forces. An improperly sized or weighted battery can destabilize the forklift, increasing rollover risk and operator danger. Dimensions must fit securely in the battery compartment to prevent movement or damage during use.

Manufacturers and safety standards require matched weight and dimensional specifications. Redway Battery strictly adheres to these safety mandates, ensuring every battery pack contributes to vehicle stability while delivering peak power.

What Are the Customization Options for Forklift Battery Sizes?

Customization of battery size includes adjusting physical dimensions, voltage, capacity, terminal location, cable length, and connector types. This flexibility meets unique forklift model demands or specific industry requirements such as longer runtime or higher power output.

Redway Battery’s OEM/ODM capabilities enable tailored battery packs for all industrial sectors, including playground vehicles, ensuring enhanced reliability and application-specific performance.

Redway Expert Views

“At Redway Battery, precision in battery size and performance is crucial for forklift safety and efficiency. Our extensive experience in OEM lithium battery manufacturing allows us to deliver tailor-made solutions that align perfectly with any forklift model. By harmonizing size, weight, and electrical output, we help businesses reduce downtime and improve energy efficiency while promoting safer forklift operation.”

Summary of Key Takeaways

• Forklift battery size charts provide essential specs for proper battery fit and function.

• Dimensions, voltage, amp-hour capacity, and weight classify batteries for compatibility.

• Most common sizes include 24V, 36V, 48V, and 72V systems.

• Using the correct battery size is critical for forklift stability, safety, and efficiency.

• Different forklift brands have distinct battery size requirements.

• Lithium batteries from Redway Battery match standard sizes but offer superior benefits.

• Weight and dimensions directly impact forklift operational safety.

• Custom battery size options cater to specialized forklift applications.

FAQs

1. How do I read a forklift battery size code?
The code indicates the number of cells (voltage), plate design, and plate count, guiding model and capacity identification.

2. Can I use any forklift battery size if the voltage matches?
No, physical dimensions and weight must fit the forklift for safety and performance.

3. Why are lithium forklift batteries gaining popularity?
They offer longer life, lighter weight, faster charging, and lower maintenance than lead-acid options.

4. Does Redway Battery provide custom forklift battery solutions?
Yes, Redway Battery specializes in OEM/ODM customization for all forklift battery sizes and specifications.

5. What happens if the forklift battery doesn’t fit properly?
Improper fit can cause instability, electrical issues, and safety hazards during forklift operation.

Forklift Battery Type EO refers to a UL (Underwriters Laboratories) classification for industrial lead-acid batteries designed with electrolyte containment and spill-resistant venting. These batteries are built for durability in heavy-duty applications, ensuring safer operation in environments like warehouses. EO types prioritize leak prevention, reduced maintenance, and compliance with ANSI B186 safety standards, making them ideal for electric forklifts handling prolonged shifts.

Understanding the Types of Forklift Batteries – A Comprehensive Guide

How does Type EO differ from other forklift battery types?

Type EO batteries are defined by their robust electrolyte management, unlike standard flooded or AGM designs. They incorporate sealed vents and corrosion-resistant trays to minimize acid leakage risks, meeting stricter UL 3108 requirements compared to Type E batteries. Pro Tip: EO types work best in multi-shift operations where battery handling frequency increases spill potential.

Unlike standard forklift batteries, EO variants use thicker separators and reinforced casing to contain sulfuric acid under tilt conditions up to 15 degrees—critical when forklifts navigate uneven surfaces. For example, a 36V 750Ah EO battery can operate 8–10 hours with fewer water top-ups than conventional models. However, they’re 8–12% heavier due to added safety components. Why does this matter? Facilities with frequent battery swaps benefit from EO’s reduced maintenance despite higher upfront costs.

What are the key safety features of Type EO batteries?

Type EO’s primary safety innovations include acid-neutralizing vent caps and double-walled containment to prevent workplace hazards. These features align with OSHA 1910.178(g) standards for reducing electrolyte exposure during charging or collisions.

Beyond spill resistance, EO batteries integrate thermal runaway prevention via flame-arresting vents that dissipate hydrogen gas safely. For instance, during rapid charging cycles, their venting systems reduce gas buildup by 30% compared to Type E. Pro Tip: Pair EO batteries with UL-listed chargers to maintain safety certifications. Practically speaking, facilities handling flammable materials can’t risk acid spills—EO’s containment trays add a critical layer of protection. Did you know? A single forklift battery spill can cost $5,000+ in cleanup and downtime, making EO’s design a long-term cost-saver.

Are Type EO batteries compatible with all forklifts?

EO batteries fit most electric forklifts but require compatible voltage and tray dimensions. Always verify ANSI B185.1 tray specs and connector types before retrofitting.

While EO batteries are standardized for Class I/II forklifts, some older models lack the necessary clearance for their bulkier trays. For example, swapping a 48V 600Ah EO battery into a 2010-era forklift may require tray modifications. Pro Tip: Check the manufacturer’s amp-hour (Ah) rating—using a higher-capacity EO battery can strain older charging systems. Transitionally, many warehouses now phase out non-EO models to streamline safety protocols. What’s the fix? Consult OEM guidelines or Redway Battery’s cross-compatibility charts to avoid mismatches.

How do you maintain a Type EO forklift battery?

EO batteries need monthly voltage checks and quarterly terminal cleaning to sustain performance. Their spill-resistant design reduces but doesn’t eliminate maintenance.

Unlike flooded batteries requiring weekly watering, EO types use recombinant vents that recapture 95% of water vapor. Still, terminals should be cleaned with a baking soda solution to prevent sulfate buildup. For example, a neglected EO battery might lose 15% capacity annually due to corroded connections. Pro Tip: Use infrared thermometers during charging—hotspots above 120°F indicate failing cells. Transitionally, facilities often pair EO batteries with automated watering systems to extend intervals to 6–8 weeks. But isn’t watering counterintuitive for EO? Yes, but even sealed systems lose微量水分 over time.

What’s the lifespan of a Type EO battery?

Properly maintained EO batteries last 5–7 years, delivering 1,500–2,000 cycles at 80% depth of discharge. Their thick lead plates resist sulfation better than standard models, enhancing longevity.

Factors like discharge depth and ambient temperature heavily impact lifespan. In refrigerated warehouses (40°F), EO batteries may achieve 2,200 cycles, while high-heat environments (95°F) cut that by 30%. Pro Tip: Avoid partial charges—EO batteries perform best when cycled from 100% to 20% consistently. Practically speaking, a 48V 800Ah EO battery operating in three shifts daily would require replacement every 4.5 years. Why such variance? Cycling frequency and charging practices directly affect plate degradation rates.

What Are Electric Forklift Batteries?

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Forklift batteries primarily fall into three categories: lead-acid (flooded or sealed), lithium-ion (LiFePO4/NMC), and hydrogen fuel cells. Lead-acid dominates industrial use due to lower upfront costs, while lithium-ion offers faster charging and zero maintenance. Fuel cells excel in continuous operations but require hydrogen infrastructure. Each type varies in energy density, lifespan, and operational protocols.

Understanding the Types of Forklift Batteries – A Comprehensive Guide

What defines a lead-acid forklift battery?

Lead-acid batteries use sulfuric acid electrolyte and lead plates. Common subtypes include flooded (requiring watering) and VRLA (valve-regulated, maintenance-free). They deliver 48V–80V systems with 1,200–2,000 cycles if maintained. However, they release hydrogen gas during charging, demanding ventilated spaces.

Lead-acid batteries operate through electrochemical reactions between lead dioxide and sponge lead. A typical 48V 600Ah flooded battery weighs ~1,100 kg, offering 28.8 kWh capacity. Pro Tip: Equalize charge flooded batteries monthly to prevent sulfation. For example, a warehouse using 80V lead-acid packs might allocate 8–10 hours for charging and cooling. These batteries suit multi-shift operations where downtime is manageable. However, their 70–80% depth of discharge (DoD) limit means oversizing for high-demand scenarios. Practically speaking, regular maintenance like checking electrolyte levels is non-negotiable. But what if watering is neglected? Stratification occurs, corroding plates and slashing cycle life. Lithium-ion alternatives avoid this but cost 2–3x upfront.

How do lithium-ion forklift batteries differ?

Lithium-ion variants employ LiFePO4 or NMC cells, providing higher energy density (150–200 Wh/kg vs. lead-acid’s 30–50 Wh/kg). They support 3,000–5,000 cycles at 80–100% DoD and charge in 1–3 hours without cooling breaks.

Unlike lead-acid, lithium-ion batteries use battery management systems (BMS) to monitor cell voltage and temperature. A 48V 600Ah LiFePO4 battery weighs ~600 kg, saving 45% space. Pro Tip: Avoid charging below 0°C to prevent lithium plating. For example, a refrigerated warehouse might opt for lithium-ion’s cold-charging capabilities (with preheating) versus lead-acid’s failure risk. Transitioning from lead-acid? Ensure charger compatibility—lithium needs constant current/voltage (CC/CV) profiles. But why the higher upfront cost? Reduced labor (no watering) and longer lifespan offset this over 5–7 years. Practically speaking, lithium’s 95% efficiency outperforms lead-acid’s 70–80%, cutting energy bills.

What are hydrogen fuel cell forklift batteries?

Hydrogen fuel cells generate electricity via oxygen-hydrogen reactions, emitting only water. They refuel in 3–5 minutes, ideal for 24/7 operations. However, they require onsite hydrogen storage and face infrastructure hurdles.

Fuel cell systems pair hydrogen tanks (~350–700 bar pressure) with proton-exchange membranes. A 20 kW fuel cell provides 8–10 hours runtime, akin to diesel but emission-free. Pro Tip: Pair with solar-powered hydrogen electrolyzers for green logistics. For example, Amazon deployed fuel cell forklifts in Texas, reducing refueling downtime by 75%. Yet, hydrogen’s flammability demands stringent safety protocols. Transitionally, fuel cells suit high-throughput environments where lithium-ion charging intervals disrupt workflow. But how scalable is this tech? Current costs (~$30,000 per unit) and sparse hydrogen stations limit adoption outside niche applications.

Comparing battery lifespans and cycle counts

Cycle life varies by chemistry: lead-acid (1,200–2,000 cycles), lithium-ion (3,000–5,000), and fuel cells (10,000+ hours). Degradation factors include DoD, temperature, and maintenance.

Lead-acid lifespan drops 30% if discharged beyond 80% DoD, whereas lithium-ion handles 100% DoD gracefully. For instance, a lithium battery cycled twice daily lasts 6–10 years versus lead-acid’s 3–5. Pro Tip: Track cycle counts via BMS to schedule replacements preemptively. Temperature plays a role too—lithium-ion loses 20% capacity at -20°C, but fuel cells thrive in subzero climates. Practically speaking, cycle life isn’t the sole metric; calendar aging affects lithium-ion (10–15 years) versus lead-acid’s 5–7. So, which matters more for your operation? High-cycle applications favor lithium, while sporadic use may tolerate lead-acid.

Cost analysis: Lead-acid vs. lithium-ion

Lead-acid costs $5,000–$10,000 upfront versus lithium-ion’s $15,000–$30,000. However, lithium’s 3x longer lifespan and 30% lower energy costs yield 40% TCO savings over a decade.

A 48V 600Ah lead-acid battery costs ~$8,000 but requires $2,000 annually for maintenance and replacement. Lithium-ion’s ~$20,000 initial investment slashes labor (no watering) and energy use. For example, a logistics firm switching to lithium saved $12,000/year per forklift. But what about disposal? Lead-acid boasts 98% recyclability, whereas lithium recycling is evolving. Transitionally, ROI hinges on utilization—high-use operations recoup lithium costs faster. Pro Tip: Lease lithium batteries to offset upfront expenses. However, hydrogen fuel cells’ TCO is higher due to infrastructure, averaging $20–$30 per hour of runtime.

Environmental impact and recycling options

Lead-acid recycling rates hit 98% in the US, but smelting emits CO2. Lithium-ion recycling is at 50–70%, while fuel cells produce zero emissions but rely on hydrogen sourcing (grey vs. green).

Lead-acid batteries are dismantled into lead (reused), plastic (reprocessed), and acid (neutralized). Lithium-ion recycling recovers cobalt, nickel, and lithium—a $10–$15/kWh cost. For instance, Redwood Materials reclaims 95% of lithium cells’ metals. Hydrogen’s eco-impact depends on production: grey hydrogen (from methane) emits CO2, while green (from renewables) is clean. Pro Tip: Partner with certified recyclers—improper lithium disposal risks fines. But is recycling enough? Transitioning to lithium reduces warehouse emissions by 40%, but sourcing ethical cobalt remains contentious. Practically speaking, fuel cells are greener if hydrogen is sustainably produced, but infrastructure gaps persist.

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Forklift Lithium Battery