When does a 72V 300Ah forklift battery make sense, and how does it differ from 80V?

Direct answer: That choice is not open: the truck’s system voltage is fixed by its motor controller, contactors and charger, so the battery must match the truck’s rated voltage. A 72V 300Ah pack makes sense only for a 72V truck, an 80V pack only for an 80V truck. Read the data plate, then compare the two packs on dimensions, weight, current and charging within that class.

Page figures. 72V 300Ah: 76.8V nominal, 300Ah, 23.04 kWh, operating range 60–87.6V, 800 × 550 × 400 mm, 235–245 kg, 150A continuous charge and discharge, 300A peak, IP65, more than 4,000 cycles at 80% DOD. 80V 300Ah: 83.2V nominal, 315Ah, 26.21 kWh, 65–94.9V, 767 × 588 × 450 mm, about 176 kg, 150A charge, 300A continuous discharge, 1000A for 5s, IP54, “5 years or 3500 cycles (DOD 70% 0.25C)”. The 72V page is less detailed: its spec figures sit in an FAQ table, and the peak duration is not stated.

Why they are not interchangeable. The voltage windows overlap only partly. A 72V truck’s controller and charger are designed around the lower window, and an 80V pack would exceed it at full charge; an 80V truck would see a 72V pack as nearly empty. Changing battery voltage is a truck modification that needs the truck maker’s written approval under OSHA’s truck rule, which in practice means it is rarely done.

Comparing within a class. For an 80V truck, compare the 80V 300Ah with the 80V 400Ah (34.94 kWh, 950 × 736 × 450 mm, about 280 kg) on energy per shift and fit; see 80V model selection. For a 72V truck, compare the 72V 300Ah against the compartment and the truck’s battery weight range, and ask Redway for a full spec sheet, since several values (peak duration, connector type) are not stated on that page.

Current. The 80V 300Ah lists 300A continuous; the 72V lists 150A continuous with a 300A peak. If the truck’s controller draws more than 150A for long periods, the 72V pack may limit performance. Check the controller rating.

Charger and connector. Each needs a charger set for its own voltage window and, where required, communication with the BMS. Label chargers by voltage so a 72V and an 80V truck are never cross-connected.