Full Specifications of the FL83630 Heavy Duty Forklift Lithium Battery
Everything an engineer needs to check this heavy duty forklift battery against a compartment drawing and a charger spec, in one table.
| Electrical Specifications | Mechanical Specifications | ||
| Nominal Voltage | 83.2V | Dimensions (LxWxH) | 1028*999*784mm |
| Nominal Capacity | 630Ah | Weight | 2100kg |
| Energy | 52416Wh | Case Material | SPCC |
| Self Discharge | <3% per month | IP Rating | IP54/IP65/IP67 |
| Cycle Life | >4000 cycles | Cell Type | LiFePO4 |
| Charge & Discharge Specifications | Temperature & Other Specifications | ||
| Charge Current | 200A | Charge Temperature | 0°C to 55°C / 32°F to 131°F |
| Charge Cut-off Voltage | 94.9V | Discharge Temperature | -20°C to 60°C / -4°F to 140°F |
| Charge Terminal/Connector | REMA | Storage Temperature | 10°C to 45°C / 50°F to 113°F |
| Discharge Current | 200A | Display | LED Display |
| Discharge Cut-off Voltage | 71.5V | Communication | RS485/CAN |
| Discharge Terminal/Connector | REMA | Shipping Classifiation | UN3480, Class9 |
Send three things and we will confirm the fit before you order
The question every buyer asks first is whether the pack drops into the tray that is already on the truck. You do not need a spec sheet to find out. Send the truck make and model, the battery compartment dimensions, and the weight of the lead-acid unit coming out. Our engineering team replies with a written fit assessment, the counterweight mass we would add, and any adjustment your truck needs.
- Truck make and model
- Compartment dimensions, or a photo of the data plate
- Weight of the battery being replace
Why Fleet Buyers Specify This High Capacity Lithium Forklift Battery for Multi-Shift Work
Because 52,416 Wh sits in one case and the voltage stays flat all the way down. LiFePO4 holds output from a full charge to the 71.5 V cut-off, so a mast lift in hour seven moves at the speed it did in hour one. The mid-shift sag that pushes a lead-acid fleet into a swap simply does not arrive, and 83.2 V nominal is what a 26-cell lithium string gives you in place of a conventional 80 V system. Specified this way a forklift lithium battery becomes a fixed asset on the truck rather than a consumable the warehouse handles every day.
The 2,100 kg is deliberate. Iron counterweights are specified so the pack reproduces the ballast of the unit it replaces, which keeps truck stability inside its original design envelope instead of leaving the operator to discover the difference on a loaded mast. CAN and RS485 push state of charge and cell temperature straight into the truck controller, and because the SPCC case is sealed there is no watering, no equalisation, and no ventilated charging room to plan around.
What a Wholesale 630Ah Heavy Duty Forklift Battery Changes on Your Budget Sheet
It goes back in the same tray
Case dimensions, the 2,100 kg ballasted mass and REMA terminals are matched to the compartment already on the truck, with counterweights tuned to close the last gap. No chassis modification line item, no rebuilt charging bay, and the truck is back on shift the same day rather than sitting through a retrofit week.
One pack per truck, not three
200 A charge current means the pack tops up during breaks and shift changes, with no memory effect and no sulfation penalty for partial charges. You stop buying the second and third forklift battery per truck, stop paying someone to swap them, and get the floor space of the charging room back for pallets.
Freezer runtime without oversizing
Capacity holds above 80% at -10°C and above 70% at -20°C, and the optional self-heating build works down to -40°C. Cold chain sites can order the same 630 Ah configuration used in ambient areas instead of paying for extra capacity that only exists to cover cold derating.
| Lead-acid | FL83630 LiFePO4 | |
|---|---|---|
| Voltage under load | Falls through the shift | Flat to 71.5 V cut-off |
| Charging | Full cycle plus cool-down | Opportunity charging at 200 A, no cool-down |
| Routine labour | Watering, equalising, cleaning | Sealed, none of the above |
| Packs per truck | Two or three plus a swap station | One |
| Capacity near freezing | Loses roughly 30–50% | Above 80% at -10°C |
| Service life | Replaced on a short interval | 4,000+ cycles, 5 to 10 years |
Energy cost reduction
Maintenance savings
Productivity increase
Space savings
Pricing depends on IP class, counterweight mass and protocol mapping, so there is no shelf price worth quoting. Tell us the fleet size and Polinovel comes back as a factory-direct forklift battery supplier with a configured number.
How Polinovel Builds Every Grade-A Cell Forklift Lithium Battery In Its Own Factory
Five controlled stages on our own line, which is what makes cell-to-cell consistency something you can audit rather than something we assert.
Raw material selection
Grade-A cells only, with cabling and hardware qualified against the same incoming inspection standard. Off-grade and reclaimed cells are the usual root cause of early capacity divergence in industrial packs, and screening them out at intake is what makes a five-year warranty affordable to honour.
Cell grading
Cells are sorted by capacity, voltage and internal resistance before any of them enter a module. Tight grouping stops the weakest cell from defining the usable window of the whole pack, which is how the 4,000-cycle figure survives five years in a working fleet instead of only on a test bench.
Laser module welding
Cells are fixtured and laser welded into modules. Welded joints hold their resistance under the vibration of a loaded truck crossing broken yard concrete, so the loose busbar that turns up as a hot connection in year two is designed out rather than inspected for.
Assembly and BMS integration
Acquisition lines are welded, the BMS is installed and wired, and the modules are fixed into the impact-resistant SPCC enclosure. Sealing is verified to the IP class you ordered, so a washdown bay or an open port apron is a decision made at order time rather than a problem discovered in the field.
Final testing
Charge and discharge, safety, functional and performance tests run on every unit before release. The records travel with the serial number, so an engineer receiving fifty packs can reconcile any single one against its own as-built data.
Where This Project Ready Heavy Duty Forklift Battery Works in Warehousing, Cold Storage and Ports
Six environments this forklift lithium battery is specified into, and the site condition each configuration answers.
Warehousing and distribution
Topping up during breaks carries a high-throughput site through consecutive shifts on a single pack, which takes the swap station and the labour around it out of the operating plan.
Cold storage facilities
Order the heating option and the pack runs reliably to -40°C. Food processing and pharmaceutical freezers keep rated runtime where lead-acid gives up a third of its capacity near freezing.
Manufacturing plants
Sustained 200 A discharge covers repeated high-mast lifts on a continuous line, inside a case built for the heat, swarf and vibration of a working plant floor.
Ports and intermodal yards
Salt-laden humidity, vibration and temperature swings are handled by the sealed case at IP65 or IP67, keeping container handling equipment on shift with very little service attendance.
Retail distribution centres
Variable shifts and seasonal peaks are absorbed by fast recharge and maintenance-free operation, so peak-season headcount goes to picking rather than to handling batteries.
Outdoor industrial yards
Dust, rain and a -20°C to 60°C discharge range are covered by the standard build, which is what lets a yard fleet drop the seasonal battery rotation altogether.
Custom OEM Manufacturing for Your 83.2V 630Ah Forklift Battery Programme
Send the truck model, the compartment drawing and the minimum ballast the chassis needs. That is enough to start, because Polinovel is a forklift battery OEM manufacturer that builds around the compartment rather than asking the compartment to accept a catalogue box.
Set at order: voltage and capacity across the 80V, 96V, 120V and 144V platforms; enclosure dimensions and iron counterweight mass; IP54, IP65 or IP67 sealing; CAN or RS485 mapping to your controller; LED display layout; self-heating for freezer duty; and connector type. Packs in this class already run under trucks from Toyota, Hyundai, Jungheinrich, Kalmar and STILL, so there is usually a tray and protocol precedent for your model on file.
Private-label builds and buyer-specified marking run on the same line as our own production, under the same test records.
Certifications and Factory Testing Behind Every Polinovel Forklift Battery
UN38.3
IEC 62619
UL 2580
CE marking
RoHS
ISO 9001 and IATF 16949 production systems
The plant runs to ISO 9001 quality management and the IATF 16949 automotive standard. If your quality team audits vendors, the process control evidence already exists in the format they ask for and does not have to be assembled ahead of a visit.
Testing done here, not sampled elsewhere
Performance, safety, extreme temperature and high-current discharge testing run in our own laboratory. Certificate copies and the test report for your forklift battery are released with the shipping documents, so compliance arrives with the goods instead of following them by email.
Packaging and UN3480 Class 9 Shipping on Bulk Order Forklift Battery Volumes
Packs ship as UN3480 Class 9 dangerous goods at the state of charge the regulation requires, with the UN38.3 test summary in the document set. Declaration wording, marking and labelling are prepared here, so your forwarder receives a file that clears without a round of corrections.
Each 2,100 kg forklift lithium battery is crated for forklift and crane handling and secured against the vibration and humidity of an ocean leg. Sea freight is standard on volume orders, air freight is possible where the destination and carrier accept Class 9 lithium cargo, and consolidated multi-pack shipments or a buyer-nominated forwarder are both routine.
MOQ, Lead Times and Warranty for the FL83630 Heavy Duty Forklift Battery
Standard build
Catalogue configuration with the standard enclosure, IP rating and connector. Order quantity and the production window are confirmed in writing on the quotation against current line loading, not estimated verbally.
Custom and OEM build
Changes to the enclosure, ballast, protocol mapping or heating add a drawing approval and a first-article stage before series production. Both dates appear on the quotation before you commit to anything.
Trial unit before a fleet rollout
Running one forklift lithium battery on one truck first is supported, including protocol validation against your controller. Trial terms are quoted separately from series pricing so the pilot does not lock in the fleet price.
Fleet conversions are usually phased. Tell Polinovel how many trucks are in scope this year and we will put the wholesale forklift battery pricing and the delivery schedule on the same page.
Procurement FAQs About the 83.2V 630Ah Heavy Duty Forklift Lithium Battery
How long will the FL83630 last in a working fleet?
Beyond 4,000 deep cycles at 80% depth of discharge under normal conditions, which in typical forklift duty is five to ten years of service. Polinovel, as a heavy duty forklift battery manufacturer, backs the pack with a five-year warranty and holds the per-unit test record for its full service life.
Can it replace our lead-acid battery without modifying the truck?
Yes, it is engineered as a drop-in replacement. Case dimensions, the 2,100 kg ballasted mass and REMA terminals are matched to the compartment, and counterweights close any remaining gap. Send your truck model and compartment drawing and our engineers return a written compatibility assessment naming anything that needs adjusting before you order.
How does it perform in a freezer compared with lead-acid?
Capacity stays above 80% at -10°C and above 70% at -20°C, where lead-acid typically loses 30 to 50% near freezing. Discharge is rated from -20°C to 60°C, and the optional self-heating build extends safe operation to -40°C for pharmaceutical and food cold storage.
What does total cost of ownership look like against lead-acid?
The purchase price is higher and the lifetime cost is lower. The difference accumulates through higher charge and discharge efficiency, no watering or equalising labour, a much longer replacement interval, and opportunity charging that removes the spare battery pool. Fleets converting from lead-acid report roughly 35% lower energy cost and 80% lower maintenance spend.
Will it talk to our forklift control system?
Yes, over CAN and RS485. State of charge, state of health, cell temperature and operating data are available in real time to the truck controller and to fleet software. Polinovel, as a forklift battery supplier with BMS integration in house, maps the protocol to your controller as part of the build rather than shipping a generic default.
Is 630Ah more capacity than we actually need?
Sometimes, and it is worth checking before you buy. This configuration suits heavy duty trucks running long shifts under high loads. If your duty cycle is lighter or your compartment is smaller, a lower-capacity pack from the same platform will cost less and fit better, and we will say so. Send your shift pattern and average load and we will size it honestly.
What documentation ships with the order?
The UN38.3 test summary, the UN3480 Class 9 declaration and marking, applicable IEC 62619, UL 2580, CE and RoHS certificates, and the final test record tied to each serial number. Polinovel prepares the file before dispatch so customs and your forwarder receive a complete set with the goods.
Request a Quote from Polinovel, Your Forklift Lithium Battery Manufacturer
Include the truck model, the compartment size and the quantity, and the reply comes back with a configured price and a fit assessment rather than a price range. Inquiries are answered by an engineer, usually within one working day.
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