80V 300Ah, 400Ah or 700Ah: which lithium battery suits heavy counterbalance trucks?

Direct answer: Compare kWh, voltage window, size, weight and charge current, not the Ah in the title. By the published tables the three are 26.21 kWh, 34.94 kWh and 55.2 kWh. The truck maker’s battery range, compartment and handling equipment decide which of them can be used at all.

Titles and tables differ. The “80V 300Ah” page lists 83.2V, 315Ah and 26.21 kWh. The “400Ah” page lists 83.2V, 420Ah and 34.94 kWh. The “700Ah” page lists 80V nominal, 690Ah and 55.2 kWh. Use the kWh and the model code on the quote, not the title.

Electrical limits: the 300Ah pack lists 150A charge, 300A continuous, 1,000A peak for 5 seconds and 10 kW output. The 400Ah pack lists 200A charge, 300A continuous, 1,000A peak for 5 seconds and 12 kW. The 700Ah pack lists 200A charge, 420A continuous and 700A peak for 30 seconds. Peak figures use different durations, so do not rank them. Operating voltage windows also differ (65–94.9V for the first two, 62.5–91.25V for the 700Ah), so check that the truck controller accepts the pack’s range.

Size and weight are the practical limits. The 300Ah pack is 767 × 588 × 450 mm and about 176 kg. The 400Ah pack is 950 × 736 × 450 mm and about 280 kg. The 700Ah pack is 1,008 × 831 × 748 mm and about 1,227 kg. OSHA requires a conveyor, overhead hoist or equivalent equipment for handling batteries (29 CFR 1910.178(g)(4)), so check your lifting gear, floor and truck compartment before you check price.

Charging has a simple floor: Ah ÷ charge amps gives about 2.1 hours for 315Ah at 150A, about 2.1 hours for 420Ah at 200A and about 3.5 hours for 690Ah at 200A, before taper. Compare that with your shift pattern and charging windows. Read our post on opportunity charging for multi-shift use if trucks will be topped up between shifts.

Truck approval is the gate. OSHA says changes that affect capacity and safe operation need the truck manufacturer’s prior written approval (1910.178(a)(4)). Ask the truck maker whether each pack is acceptable for your model, and ask Redway for a dimensioned drawing and written confirmation of fit and duty. Approved truck models and ballast options are not published on the product pages.