Designed for high-performance reach trucks, this robust lithium battery excels in demanding warehouse environments, including tight aisles, heavy lifting, and multi-shift operations. Utilizing cutting-edge LiFePO4 technology, it delivers reliable power, rapid recharge, and extended cycle life-enabling operators to keep trucks running longer, reduce downtime, and optimize overall material handling efficiency.
What Makes This Lithium Battery Better
Advanced LiFePO4 technology ensures efficiency, safety, and extended battery life.
Longer Lifespan
Our 36V lithium battery supports over 4,000 charge cycles, lasting up to 10 times longer than traditional batteries and greatly lowering replacement expenses.
Rapid Charging
Reach a full charge in just 1–2 hours, cutting downtime and keeping your operations running efficiently compared to conventional forklift batteries that need 8–10 hours.
Enhanced Safety
Equipped with complete safeguards against overcharging, deep discharge, short circuits, and thermal hazards, this battery ensures reliable, consistent performance.
High Power Density
With greater power output than conventional lead-acid batteries, this lithium battery provides quick acceleration and stable performance, even when handling heavy loads.
Technical Specifications
| Electrical Specifications | Mechanical Specifications | ||
| Nominal Voltage | 38.4V | Dimensions (LxWxH) | 980*460*787mm |
| Nominal Capacity | 920Ah | Weight | 1050kg |
| Energy | 35328Wh | Case Material | SPCC |
| Self Discharge | <3% per month | IP Rating | IP54 |
| Cycle Life | >4000 cycles | Cell Type | LiFePO4 |
| Charge & Discharge Specifications | Temperature & Other Specifications | ||
| Charge Current | 250A | Charge Temperature | 0°C to 55°C / 32°F to 131°F |
| Charge Cut-off Voltage | 43.8V | 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 | 250A | Display | LED Display |
| Discharge Cut-off Voltage | 33V | Communication | RS485/CAN |
| Discharge Terminal/Connector | Anderson | Shipping Classifiation | UN3480, Class9 |
38.4V
Nominal Voltage
920Ah
Capacity
35.3kWh
Total Energy
4000+
Cycle Life
What This Battery Delivers
The FL38920 is a drop-in lithium iron phosphate battery designed specifically for reach truck applications. It replaces standard 36V lead-acid batteries without requiring vehicle modifications, fitting the same compartment dimensions while delivering significantly different performance characteristics.
Primary applications include:
Multi-shift warehouse operations where equipment runs 16+ hours daily
Cold storage facilities operating between -20°C and 60°C
High-throughput distribution centers with narrow aisle configurations
E-commerce fulfillment operations with variable demand cycles
The core value proposition centers on three measurable outcomes: 75% reduction in charging time (1-2 hours versus 8-10 hours for lead-acid), elimination of watering and equalization maintenance, and a cycle life exceeding 4,000 charges-roughly 10 times longer than conventional alternatives.
75%
Faster Charging Time
Zero
Maintenance Required
10×
Longer Cycle Life
Key Capabilities That Affect Daily Operations
Opportunity Charging During Breaks
Unlike lead-acid batteries that require full discharge-charge cycles, the FL38920 accepts partial charges without capacity degradation. Operators can plug in during 15-minute breaks or lunch periods and recover 15-25% capacity. This flexibility means a single battery can support continuous multi-shift operations without swap-outs.
In practice, a facility running two 8-hour shifts can often operate with one lithium battery per truck instead of the two or three lead-acid sets previously required. The charging infrastructure footprint shrinks accordingly-fewer chargers, less floor space dedicated to battery storage, reduced electrical infrastructure costs.
Integrated Battery Management System
The smart BMS continuously monitors cell voltages, temperatures, and current flow across all battery modules. When it detects an anomaly-a cell running warmer than its neighbors, for instance-the system adjusts charging parameters automatically and logs the event for maintenance review.
Protection circuits prevent overcharge conditions , deep discharge, overcurrent events, and short circuits. These safeguards operate passively; operators don't need to monitor battery status or manage charging profiles manually.
Real-Time Status Display
The integrated LED display shows state of charge, voltage, current draw, and fault codes without requiring handheld diagnostic tools. Operators can check remaining runtime before starting a picking sequence, and maintenance staff can identify issues without connecting external equipment.
Fleet Integration via CAN Bus
RS485 and CAN communication protocols let the battery exchange data with the truck's control system and, where installed, facility-wide fleet management platforms. This connectivity enables features like automated fault reporting, usage pattern analysis, and predictive maintenance scheduling. Warehouses using telematics systems can pull battery health data into their existing dashboards.
Installation and Ongoing Maintenance
Initial Setup
Physical installation mirrors standard battery replacement-the FL38920 uses industry-standard mounting configurations and connector types. Most facilities complete the swap in under an hour per truck. However, optimal performance requires matching the charger to lithium-specific profiles. Existing lead-acid chargers won't work; you'll need compatible units that support the higher charge rates and voltage parameters.
For fleets transitioning from lead-acid, plan the changeover truck by truck rather than all at once. This approach lets you validate charger compatibility, train operators on the different usage patterns, and identify any vehicle-specific issues before full deployment.
Day-to-Day Operation
Daily maintenance requirements essentially disappear. There's no watering schedule, no equalization charges, no acid level checks. The BMS handles cell balancing automatically. Operators connect the charger when convenient and disconnect when ready to work-that's the extent of routine interaction.
Periodic checks should verify connector integrity and confirm the display shows normal readings. Most facilities incorporate this into existing pre-shift inspection routines. Expect to spend roughly 5 minutes per week per battery on visual inspections versus 30+ minutes per week for lead-acid maintenance.
System Integration
Connecting the battery to fleet management systems requires CAN bus or RS485 interfaces on your existing infrastructure. If your facility already uses telematics for vehicle tracking, adding battery monitoring typically involves configuration changes rather than new hardware. Facilities without existing connectivity can operate the batteries standalone-fleet integration is optional.
Initial Investment
Lithium systems require a higher upfront investment than lead-acid, often several times the purchase price for comparable capacity. For the FL38920, the primary cost components include the battery itself and compatible charging equipment. Facilities using lead-acid chargers should plan for lithium-specific units to ensure correct voltage and charging profiles.
However, overall battery inventory requirements typically decrease once opportunity charging becomes available. Operations that previously relied on multiple lead-acid batteries per truck can often operate with a smaller lithium battery pool, partially offsetting the higher unit cost.
Operating Cost Reductions
Lithium technology lowers operating expenses across several areas:
Maintenance labor: No watering, equalization, or rotation routines, resulting in significantly fewer service hours per truck each year.
Energy consumption: Higher charging efficiency reduces electricity consumption compared with lead-acid systems.
Infrastructure: Smaller battery rooms, reduced ventilation requirements, fewer charging stations
Replacement cycles: 4,000+ cycle life versus 300-500 cycles means fewer replacement purchases over equipment lifetime
Productivity Gains
The harder-to-quantify benefit is increased equipment availability. When trucks don't sit waiting for battery changes, throughput increases. Facilities typically report 5-12% productivity improvements from reduced changeover time alone. For a warehouse moving $50 million in goods annually, even a 5% throughput increase represents substantial value.
Payback Timeline
Based on typical multi-shift warehouse operations, the payback period ranges from 2 to 4 years depending on utilization intensity and local electricity costs. Facilities running three shifts see faster returns than single-shift operations. Cold storage applications often achieve payback faster due to the performance advantages in low-temperature environments.
The payback results from a combination of lower operating expenses, reduced battery inventory, and productivity improvements. Actual outcomes vary based on fleet size, existing infrastructure, and day-to-day operating patterns.
Warranty and Support
Comprehensive Protection
The FL38920 includes a standard warranty covering manufacturing defects and premature capacity degradation. Technical support is available for installation guidance, charger compatibility questions, and troubleshooting. Firmware updates for the BMS are provided as needed to address identified issues or improve functionality.
Expected service life exceeds 10 years under normal operating conditions, based on the 4,000+ cycle rating and typical warehouse utilization patterns.
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