A fleet runs 20 trucks on a lithium pack whose original supplier has stopped making it. Two packs are failing, and the fleet engineer asks whether another factory can build a pack that fits the same trucks, talks to the same displays and uses the same chargers.
Usually yes, if you replicate the interface rather than copy the design. Record what the truck and charger see: outline and weight, mounting, connectors and polarity, voltage window, current limits, and the communication messages the truck and charger expect. A factory then designs a new pack to that interface. Check that you have the right to share any drawings, and approve a sample on a truck before ordering more.
What to record from the old pack
- Mechanical. Outline dimensions, weight (and the truck’s minimum battery weight), lifting points, mounting and cable exits.
- Electrical. Nominal voltage, operating range, capacity, connector types and positions, and fuse rating.
- Communication. The protocol and messages used by the truck display and charger, for example over CAN-bus. A short data log from a working truck is very useful.
- Behaviour. How the truck reacts at low charge, what alarms appear, and the charging profile in use.
Our compartment measuring guide and tray-fit article help with the mechanical side.
Working with a factory
Redway’s OEM services page lists reverse engineering among its services; the scope and limits for your pack should be agreed at quotation. Expect the factory to propose its own cells and BMS, then match the interface you documented. OEM custom orders have no MOQ by default (1 piece), although some specific products carry a 10-piece minimum, so confirm for your model. A first sample, tested on one truck and one charger, should come before a batch. Redway holds relevant qualifications and certifications for its batteries; details are available from sales.
IP and safety checks
- Share only drawings and data you are entitled to use. Replicating an interface is different from copying a protected design.
- Ask for new transport test documents (UN 38.3) for the new pack; the old pack’s papers do not cover it.
- Check with the truck maker whether a different pack affects the truck’s approvals or warranty.
Planning the change-over
Replace failing packs first and keep the remaining old packs running while the new design is proven. Mark trucks with the pack type they carry, and keep separate spare stock until the old packs are retired. A mixed fleet is manageable if records show which pack is in which truck.
Risk limits
A pack that fits but communicates wrongly can make a truck behave unexpectedly, so test communication carefully before use. Do not open the old pack to copy internal parts without the owner’s approval. Confirm the scope of reverse engineering for your project with Redway.
Additional perspectives
Log CAN traffic from a healthy truck before the last old pack fails. Once all packs are dead, that data is much harder to get.
Redway Tech Editorial Team – Fleet engineer perspective
Check the original supply contract for clauses on drawings and software. Interface data you measured yourself is usually easier to share than drawings you received.
Redway Tech Editorial Team – Legal counsel perspective
Ask for a quote on the sample and a fixed price for the batch at the same time. It keeps the comparison clear when you decide whether to continue after the trial.
Redway Tech Editorial Team – Procurement 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.
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