The Hyster E40XL 36V forklift requires a 36V battery with a part number 18-85-27, typically a lead-acid or lithium-ion (LiFePO4) battery. Key specs include 600–700Ah capacity, 27.5″ (L) x 18.5″ (W) x 30.5″ (H) dimensions, and around 2,200 lbs. Lead-acid models use 18 cells (2V each), while lithium variants offer 50% weight reduction and deeper discharge cycles. Verify terminal alignment (B19/B20) and charging profiles to prevent compatibility issues.
How Much Does a Forklift Battery Weigh?
What are the key specifications for a Hyster E40XL battery?
A compatible battery must match 36V nominal voltage, ~625Ah capacity, and 18-cell lead-acid configuration. Dimensions must align with 18-85-27 footprints to fit the E40XL’s tray. Pro Tip: Avoid mixing new and old lead-acid cells—imbalance accelerates sulfation and reduces lifespan by 40%.
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Beyond voltage and size, weight matters—lead-acid batteries for the E40XL weigh ~2,200 lbs, while lithium options cut this to 1,100–1,400 lbs. Terminal type (B19 or B20) is critical: reversed polarity can fry the controller. For example, a Crown GC-RM36-625 lead-acid battery uses electrolyte density of 1.280 specific gravity, requiring bi-weekly water top-ups. Why risk downtime? Lithium-ion alternatives eliminate watering but need a 36V BMS with CANBus integration for Hyster’s diagnostic systems.
| Spec | Lead-Acid | Lithium-Ion |
|---|---|---|
| Weight | 2,200 lbs | 1,250 lbs |
| Cycle Life | 1,500 cycles | 3,000+ cycles |
| Maintenance | High | Low |
Can I use lithium-ion instead of lead-acid in the Hyster E40XL?
Yes, but ensure the lithium battery has 36V output, matching Ah rating, and BMS safety protocols. Lithium batteries reduce recharge downtime by 60% but require CANBus-compatible chargers.
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Practically speaking, lithium conversions involve more than swapping cells. The E40XL’s charging port may need a J1772 connector retrofit for smart charging. Pro Tip: Check if the forklift’s motor controller supports lithium’s higher discharge rates (up to 3C). For example, Redway’s RLFP-36V-600S2 lithium pack uses IP67 enclosures to withstand warehouse dust—unlike vented lead-acid models. But what about cost? Lithium costs 2–3x upfront but lasts twice as long, slashing total cost of ownership by 30%.
How do I measure my existing Hyster battery for replacement?
Document length x width x height, terminal positions (left/right), and voltage/C-rate. Use calipers for precise tray measurements, allowing ≤1/4” tolerances.
Start by measuring the battery compartment: 27.5” x 18.5” x 30.5” is standard for 18-85-27. Don’t forget terminal orientation—B19 (right-side positive) is common. Why risk mismatched terminals? A misaligned battery won’t seat properly, causing arcing. For lead-acid replacements, verify vent cap locations match the forklift’s hydrogen venting system. Redway’s RLFP-36V series includes adjustable shims for +/- 0.5” fitment flexibility, ideal for aged battery trays with warping.
| Measurement | Lead-Acid | Lithium |
|---|---|---|
| Height | 30.5” | 28.0” |
| Width | 18.5” | 18.5” |
| Terminal Type | B19 | B20 |
What does the Hyster 18-85-27 part number signify?
18 indicates cell count (36V), 85 denotes width (inches x10), and 27 reflects length (inches x10). Always confirm Ah ratings (625Ah±5%) when cross-referencing.
Breaking it down: 18 cells x 2V = 36V nominal. The “85” translates to 8.5” width (likely rounded from 18.5”), and “27” to 27.5” length. But why does this matter? Third-party vendors often tweak dimensions by ±0.5”, risking tray incompatibility. For instance, a GreenTech GT-LFP36-600 battery lists 27.25” length, requiring tray adapters. Pro Tip: Cross-check Hyster’s OEM specs for tray load limits—lithium’s lower weight may necessitate adding ballast for stability.
What charging system works with 18-85-27 batteries?
Use a 36V charger with 40–80A output for lead-acid, or a 36V LiFePO4 charger with CC-CV phases. Lead-acid requires equalization charging weekly to prevent stratification.
For lead-acid, a Delta-Q QuikCharge 3623 delivers 65A, refilling 80% capacity in 5 hours. Lithium batteries, however, demand chargers like the Lester Summit II 36V with CANBus communication to sync with the BMS. Ever seen a charger fry a battery? Incorrect voltage limits—like charging lead-acid beyond 45.5V (2.53V/cell)—cause corrosion. Redway’s lithium kits include adaptive chargers, but legacy Hyster models may need firmware updates to accept LiFePO4 charge curves.
Where can I buy a 18-85-27 replacement battery?
Purchase from Hyster dealers, industrial battery suppliers, or custom lithium builders like Redway. Expect $4,000–$8,000 for lead-acid and $12,000–$18,000 for lithium.
Hyster’s OEM lead-acid batteries cost ~$7,500 with cores, while third-party alternatives like Enersys’s NexSys sell for $6,200. But what if you need a budget fix? Refurbished lead-acid units start at $3,500 but offer 50% shorter lifespans. For lithium, Redway’s RLFP-36V-625C integrates Bluetooth for SOC monitoring—ideal for fleets. Pro Tip: Leasing lithium batteries cuts upfront costs via monthly plans (~$300/month), including maintenance and replacement.
Redway Battery Expert Insight
FAQs
Yes, but it requires a BMS-compatible charger and potential terminal adapters. Confirm controller compatibility to avoid voltage spikes.
Does the Hyster E40XL support AGM batteries?
Yes—AGM 18-85-27 models fit identically but cost 20% more than flooded lead-acid with lower maintenance.
What if my battery part number differs slightly (e.g., 18-85-27A)?
The “A” suffix often denotes terminal orientation or Ah tweaks—consult Hyster’s manual to verify compatibility.
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