Hangcha CPD25 Forklift: Custom 48V 560Ah Lithium Battery Build

A logistics operator running a Hangcha CPD25 electric counterbalance forklift asked XiCha Part for a lithium upgrade that would drop into the original battery compartment without cutting the truck or changing the charger profile. This production case walks through the battery we built and shipped.

Truck and Requirement

Battery Design

The pack uses prismatic LiFePO4 cells in a 15S configuration with a 560Ah capacity matching the original lead-acid rating. Because lithium delivers its full rated capacity — unlike lead-acid, which is typically usable to around 80% — effective runtime per charge exceeds the truck's previous working hours.

• Steel tray dimensioned to the original DIN footprint, with reinforced lifting points for safe installation
• Smart BMS with 250A continuous discharge, cell balancing, and CAN interface reporting state of charge to the truck dash
• Interlocked connector matched to the truck's existing receptacle, plus forklift battery connectors and cables supplied in kit
• Compression padding and cell-level fusing for vibration resistance in yard duty

Charging Match

We supplied a matched 48V lithium smart charger with a lithium charge curve. Opportunity charging during breaks keeps the pack between 30–90% state of charge, the sweet spot for cycle life. No dedicated charging room or battery exchange trolley is required — the biggest daily saving for this operator.

Production and Delivery

Cells were capacity-graded and matched before assembly. After build, the pack passed a full-load discharge test, BMS protection verification (over-current, over-temperature, low-voltage cutoff) and a vibration table check. The battery shipped bolted to a pallet with cycle-life test data and installation drawings, ready for a two-person drop-in installation using a standard battery bolt and bracket set.

Result

The forklift now runs both shifts on one battery with mid-shift top-ups. Watering, acid spill cleanup and weekly equalize charges are gone from the maintenance schedule, and voltage sag under lift has visibly improved travel speed on ramps.

Running a Hangcha or similar counterbalance truck? Send us the truck model and battery compartment dimensions — XiCha Part verifies fit before production of every custom lithium forklift battery. Request a build sheet.