Full Specifications of the Polinovel 80V 460Ah Counterbalance Forklift Lithium Battery
Every value below describes model FL80460 as it leaves our line. Ingress protection, connector type and enclosure dimensions are configurable, so confirm the target truck compartment with our engineers before the order is released to production.
| Nominal voltage | 80V |
|---|---|
| Nominal capacity | 460Ah |
| Energy | 36,800Wh |
| Self discharge | <3% per month |
| Cycle life | >4,000 cycles |
| Charge current | 200A |
|---|---|
| Charge cut-off voltage | 91.25V |
| Charge terminal / connector | REMA |
| Discharge current | 200A |
| Discharge cut-off voltage | 68.75V |
| Discharge terminal / connector | REMA |
| Dimensions (L×W×H) | 1022 × 986 × 612 mm |
|---|---|
| Weight | 1800 kg |
| Case material | SPCC |
| IP rating | IP54 / IP65 / IP67 |
| Cell type | LiFePO4 |
| Charge temperature | 0°C to 55°C / 32°F to 131°F |
|---|---|
| Discharge temperature | -20°C to 60°C / -4°F to 140°F |
| Storage temperature | 10°C to 45°C / 50°F to 113°F |
| Display | LED display |
| Communication | RS485 / CAN |
| Shipping classification | UN3480, Class 9 |
A Drop-In Lithium Forklift Battery That Replaces Your Lead-Acid Pack Without Compartment Rework
Polinovel sized the FL80460 to take the place of a lead-acid pack in an 80V counterbalance truck, not to sit alongside one. The 1022 × 986 × 612 mm envelope drops into the standard compartment, and the specified 1800 kg mass means the battery keeps doing ballast duty. On a counterbalance forklift the pack is part of the load chart, and a lightweight lithium pack that ignores this forces you into added ballast or a derated capacity plate. If you're sizing a replacement pack from scratch rather than matching this exact model, our counterbalance forklift battery sizing guide walks through the voltage, capacity and ballast-weight math truck by truck.
Inside that same footprint sit 36,800Wh of LiFePO4 cells with a flat discharge curve, so lift speed and travel speed hold from a full charge down to near depletion rather than fading through the shift. REMA terminals, an LED state of charge display and RS485 or CAN output match what your truck and charger already expect. The retrofit stays a mechanical swap and a communication check instead of a rewiring project.
Why Fleet Buyers Choose This Wholesale 80V Counterbalance Forklift Lithium Battery
460Ah that stays 460Ah
The pack sustains 200A of continuous discharge with a flat voltage profile, and cycle life is rated beyond 4,000 cycles at 80% depth of discharge. Lead-acid packs are conventionally cycled far shallower to protect plate life, so their nameplate amp-hours and their usable amp-hours drift apart. Here they do not.
What that means for you: shifts get planned against the number on the data sheet, not against a derated figure an operator discovers at hour six.
One battery per truck, not three
A 200A charge current brings the 460Ah pack to full in one to two hours, and opportunity charging during breaks carries no cycle life penalty. Charge and discharge efficiency runs at 95%, against 70 to 80% for lead-acid.
What that means for you: the spare battery inventory, the change-out bay, the hoist and the swap labour all leave the budget. Warehouse floor area comes back.
No watering, no acid
This lithium forklift battery asks for no electrolyte top-up, no equalisation charging and no acid spill containment. Charging efficiency alone cuts energy draw by 15 to 30% against lead-acid, and service life reaches five to ten years under normal operating conditions.
What that means for you: maintenance headcount stops scaling with truck count, and every pack is covered by a five-year or 10,000-hour warranty.
What the total cost of ownership looks like across a five-year fleet cycle
- Up to ten times the service life of lead-acid, at 4,000+ cycles against 300 to 500, which moves replacement spend outside the five-year window entirely.
- Maintenance labour and consumables removed rather than reduced.
- 15 to 30% lower energy draw for every kilowatt-hour you put back into the pack.
- Dedicated battery rooms, wash stations and change-out infrastructure become unnecessary.
Inside the Polinovel LiFePO4 Forklift Battery: Cells, BMS and Enclosure Engineering
Why LiFePO4 chemistry for counterbalance trucks
Lithium iron phosphate is specified for its thermal and chemical stability under high-current draw, which lowers thermal runaway risk in an enclosure that sits under an operator all day. The chemistry also holds its output across the -20°C to 60°C discharge window, and Polinovel offers a self-heating option that extends reliable operation into cold-storage duty as far down as -40°C.
The SPCC enclosure and its ingress ratings
The 80V 460Ah pack is housed in SPCC steel with an automotive-grade e-coating and full sealing, available at IP54, IP65 or IP67. Choose IP67 for outdoor loading docks, wash-down zones and humid or frozen warehouses; IP54 is enough for dry indoor material handling. Sealed construction also ends acid corrosion at the terminals and around the compartment.
The battery management system behind every Polinovel forklift battery
Protection
Overcharge
Over-discharge
Short circuit
Overcurrent
Cell balancing
Balancing runs during charge, during discharge and while the truck stands idle, then recalibrates capacity so the pack reports a state of charge your operators can trust. Cell imbalance is the usual cause of premature capacity fade in industrial battery packs. Here it is managed rather than diagnosed later.
Monitoring and integration
Real-time state of charge and state of health data is published over CANbus and RS485 to the truck controller and to your fleet management system. Charge level, cell temperature and pack health arrive as data, so maintenance gets scheduled instead of triggered by a stranded truck.
How the pack charges
The charger reads pack temperature and state of charge over the communication bus and adapts its profile, which prevents overcharge at the top of the curve. Opportunity charging during breaks and shift changes is supported without shortening cycle life, and the battery accepts energy recovered from regenerative braking and mast-lowering systems.
One caution worth putting in writing: charge with a LiFePO4-profile charger only. A lead-acid charger applies the wrong termination voltage and offers no handshake with the BMS. It is the single most common cause of warranty disputes on retrofit projects, and it is entirely avoidable if the charger is specified with the battery. For the full opportunity-charging schedule and shift-pattern math behind this, see our lithium forklift battery charging best practices guide.
Where This Counterbalance Forklift Battery Works: Warehouse, Cold Storage and Manufacturing Fleets
Multi-shift distribution centres
Two and three-shift warehouses run this 80V 460Ah pack around the clock on opportunity charging alone. At 200A a thirty-minute break returns meaningful runtime, and a full recharge fits inside a shift changeover.
Cold storage and freezer aisles
Discharge is rated to -20°C, and the optional heating function holds performance to -40°C. IP67 sealing copes with the condensation cycle every time a truck leaves the freezer for the dock. Our cold storage forklift battery guide covers charger placement and staggered charging strategies for freezer fleets in more detail.
Manufacturing plants and outdoor yards
Sealed SPCC construction, vibration-resistant internals and no acid venting suit dusty plant floors, foundry aisles and unsheltered loading yards, the places where lead-acid packs corrode at the terminals first.
Custom OEM Manufacturing for Your 80V 460Ah Counterbalance Forklift Lithium Battery
Every FL80460 can be built to order. Send us the compartment drawing, the truck make and model, and the connector currently in service. Polinovel engineers return a fitted configuration rather than a catalogue substitution, and the drawing is signed off before anything reaches the line. If you're comparing suppliers before committing to a drawing, our custom battery pack manufacturer sourcing guide covers the due-diligence questions worth asking, including per-cell test reports and certification timelines.
- Enclosure envelope. Dimensions built to your compartment rather than to a standard case, so the pack seats without shimming or bracket fabrication.
- Ballast mass. An optional integrated counterweight, so the truck's rated load chart survives the retrofit.
- Ingress protection. IP54, IP65 or IP67 chosen against the duty environment rather than by default.
- Connector. REMA as standard, with alternative terminals fitted to match the charging infrastructure you already own.
- Communication. CAN or RS485 mapping aligned to your truck controller and to your fleet management platform.
- Cold-climate option. Self-heating for cold-storage and sub-zero outdoor fleets.
How Polinovel Tests and Certifies Every Counterbalance Forklift Lithium Battery
| UL 2580 | Motive power batteries, industrial vehicles |
|---|---|
| IEC 62619 | Industrial secondary lithium cells and batteries |
| UN 38.3 | Transport safety testing |
| CE | European market conformity |
| UN3480, Class 9 | Shipping classification for this pack |
What we check before a pack ships
Cell-level voltage and internal resistance grading before assembly begins.
BMS protection thresholds verified against the 91.25V charge and 68.75V discharge cut-offs.
Capacity confirmed at the rated 200A discharge.
Enclosure ingress tested to the IP class on your order.
CAN and RS485 handshake tested against the target controller wherever the truck model is supplied to us.
Every 460Ah pack leaves the line under a five-year or 10,000-hour warranty, with technical support available for as long as the battery is in your fleet.
Packaging and Shipping for Bulk Orders of Lithium Forklift Batteries
The FL80460 travels as UN3480, Class 9 dangerous goods under UN 38.3 test certification. Each battery is crated for forklift and crane handling at its 1800 kg gross mass, shipped at the state of charge the carrier's dangerous goods rules require, and released with the UN 38.3 test summary and MSDS attached to the export file.
Sea freight is standard for fleet quantities. Air freight and destination customs handling are quoted per shipment against your incoterm. If you are importing into a market with its own lithium battery rules, tell us the destination country early and we will confirm the paperwork before you book.
MOQ and Lead Times for the FL80460 Counterbalance Forklift Lithium Battery
Minimum order quantity and lead time are quoted per configuration, because both depend on whether the battery ships in the standard FL80460 envelope or in a compartment-specific enclosure. Orders in the stock 460Ah configuration enter the production schedule directly. Custom envelopes are scheduled after drawing sign-off, and in practice it is the sign-off stage, not the build stage, that sets the delivery date.
Send the truck model, compartment dimensions, connector type, required IP class and annual volume with your enquiry. The quotation comes back with firm quantities, price breaks and a production window rather than a range.
Polinovel 80V 460Ah Counterbalance Forklift Lithium Battery Gallery
Polinovel, Your Factory-Direct Counterbalance Forklift Lithium Battery Manufacturer and Supplier
Polinovel is a dedicated counterbalance forklift lithium battery manufacturer and OEM supplier, building LiFePO4 motive power packs from our Shenzhen facility for material handling equipment, airport ground support equipment, mining locomotives, aerial work platforms and AGVs.
Fleet buyers work with Polinovel as a forklift battery factory rather than as a trading intermediary. The engineers who read your compartment drawing are the same people who release it to the line, and the support desk that answers a CAN mapping question during commissioning is still there a year later.
Fit, not substitution
Polinovel builds custom enclosures matched to your forklift brand's existing compartment, including an optional integrated counterweight.
A certified build
Packs tested to UL 2580, IEC 62619, UN 38.3 and CE requirements before they are cleared for shipment.
Direct from the factory
Pricing, engineering changes and warranty claims are handled by the manufacturer, with no distributor in the chain.
Support around the clock
Commissioning support, error code diagnosis and fleet integration guidance for the working life of the battery.
Procurement FAQs About the 80V 460Ah Counterbalance Forklift Lithium Battery
Q: Will the FL80460 fit my existing 80V counterbalance truck compartment?
A: The standard enclosure measures 1022 × 986 × 612 mm and weighs 1800 kg. Where that does not match your compartment, Polinovel, as a counterbalance forklift lithium battery manufacturer with in-house enclosure engineering, builds the pack to your drawing, including an optional integrated counterweight so the truck's rated load chart is unaffected. Browse our full range of 48V-80V counterbalance forklift lithium batteries to compare capacities against your compartment before requesting a custom drawing.
Q: Can I keep my existing lead-acid charger for this lithium forklift battery?
A: No. LiFePO4 needs a charger built for the chemistry, with the correct termination voltage and a communication link to the BMS. A lead-acid charger risks overcharge, voids the warranty and shortens pack life. Specify the charger together with the battery and the problem never arises.
Q: Does opportunity charging shorten cycle life?
A: It does not. The battery accepts short top-ups during breaks and shift changes without any cycle life penalty, which is exactly what allows a single 460Ah pack to cover a multi-shift operation. A full charge at 200A takes one to two hours.
Q: What performance should I expect in a cold-storage warehouse?
A: Discharge is rated from -20°C to 60°C. For freezer duty below that, Polinovel, as a forklift battery supplier with in-house BMS development, offers a self-heating option that keeps the pack working down to -40°C. Charging should still take place between 0°C and 55°C.
Q: What service life and warranty come with this counterbalance forklift battery?
A: More than 4,000 cycles at 80% depth of discharge, which corresponds to five to ten years of normal operation, up to ten times what a lead-acid pack delivers. Coverage is a five-year or 10,000-hour warranty backed by technical support.
Q: Will the battery integrate with our fleet management system?
A: Yes. CANbus and RS485 outputs publish real-time state of charge, state of health, current and cell temperature. Supply the controller and platform details with your enquiry and Polinovel configures the CAN mapping before the pack ships.
Q: Is end-of-life disposal a compliance problem?
A: LiFePO4 contains no lead or cadmium, is non-toxic and is recyclable at end of life. The pack ships as UN3480, Class 9 under UN 38.3 certification, and it goes into standard lithium battery recycling channels rather than hazardous acid disposal.
Request a Quote from Polinovel, Counterbalance Forklift Lithium Battery Manufacturer
Include the truck make and model, compartment dimensions, connector type, required IP class and annual volume. Quotations come back with a firm price break and a production window.
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