A maintenance supervisor is replacing lead-acid forklift batteries with LiFePO4 packs and wants to reuse the existing chargers to save cost. The chargers were bought for lead-acid and have an equalisation setting nobody remembers using.
Match five things: nominal voltage, charge profile, current limit, temperature window and communication. A 48V LiFePO4 pack is 16 cells in series (51.2V nominal, 58.4V maximum charge), so the charger must be a constant-current, constant-voltage profile set for lithium with an end voltage the pack’s BMS accepts, and a current within the pack’s limit. Lead-acid chargers with equalisation or float stages generally need replacing or reprogramming with the supplier’s approval.
What to compare, with Redway’s numbers
- Voltage. Redway lists the 48V forklift packs as 51.2V nominal, with a maximum charge voltage of 58.4V and an operating range of 40V to 58.4V.
- Profile. Lithium charging is constant current followed by constant voltage. Lead-acid stages such as equalisation (a deliberate overcharge) and float do not suit LiFePO4.
- Current. The tables show continuous charge currents of 150A for the 304Ah pack, 200A for the 460Ah pack and 250A for the 560Ah pack. The charger’s output must not exceed the pack’s limit, and a lower current is fine if the charge time suits your shift.
- Temperature. Charging is specified from 0 to 55 degrees C. A charger should stop or reduce current outside the window, usually through BMS signals.
- Communication and plug. Ask whether the charger talks to the BMS (for example by CAN) or only follows a fixed profile, and confirm the connector and polarity.
How to decide
Send the charger model and settings sheet to the supplier and ask for written approval of the pairing. Ask for a pack-and-charger test before fleet purchase. Redway’s forklift battery charging page covers charger types, and the voltage and capacity guide explains the pack ratings.
Checking the pairing
Ask the supplier to run one pack on the proposed charger and send the charge log: start voltage, peak current, end voltage and time. Compare it with the data sheet limits. If the charger also supports a lead-acid profile, lock out that setting so a technician cannot select it by mistake.
Risk limits
Do not adjust charger settings on a guess. A wrong end voltage can trip protection or shorten life, and a charger with the wrong profile can be unsafe. Use only settings approved by the pack supplier, and keep the approval in the asset file. This article is general guidance and is not a substitute for the supplier’s data sheet.
Additional perspectives
Take photos of every charger data plate and settings page before ordering, and list which chargers can be reprogrammed. In many fleets, a few newer chargers can be reused and the rest should be replaced with the pack order.
Redway Tech Editorial Team – Maintenance supervisor perspective
Check that the charger’s voltage ripple and cut-off tolerance fit the BMS limits, and that the BMS can open its contactor if the charger fails to stop. Ask for a short test log showing a full charge from the supplier’s lab.
Redway Tech Editorial Team – Charger engineer perspective
Buy the pack and charger as a pair, with the pairing approved in writing. A charger bought separately can leave the pack outside its warranty or support terms if the charge profile is wrong.
Redway Tech Editorial Team – Purchasing perspective
Specifications are taken from Redway product pages as of October 2026. Where a figure isn’t published, this article says so. Confirm current specifications for your model with Redway before ordering. This article is general guidance, not a site-specific engineering assessment.
Related products
- 48V 300Ah 304Ah Forklift Lithium Battery
- 48V 460Ah 450Ah Forklift Lithium Battery
- 48V 560Ah 550Ah Forklift Lithium Battery
- 48V 420Ah 400Ah Forklift Lithium Battery
- 48V 210Ah 200Ah Forklift Lithium Battery
Related topics
- Forklift Battery Charging
- Forklift Battery Voltage & Capacity
- Forklift Charging Systems & Troubleshooting
- Forklift Fast & Opportunity Charging
- Forklift BMS, Fleet Monitoring & Telematics
- 48V Forklift Battery Systems
- Lithium vs Lead-Acid Forklift Batteries
- Forklift Battery Replacement & Conversion
- Forklift Battery Rooms, Ventilation & Compliance
- Forklift Battery Safety
Continue learning
Forklift Batteries
Related reading
