60% Weight-Saving Lightweight Lithium Battery for Heavy Truck Engine Starting

A lightweight lithium battery built for fleets that still demand lead-acid reliability. Our 24V 100Ah LiFePO4 starting battery weighs 12.5 kg, roughly 60% less than the 32 kg twin lead-acid set it replaces. For a fleet engineer, that weight saving arrives together with a cold cranking reserve that lead-acid simply cannot hold, so every truck in your fleet drops close to 20 kg of dead weight from the chassis while gaining a battery that keeps cranking long after a flooded cell would have failed. The lightweight lithium battery is assembled with grade-A prismatic cells, a 200A continuous smart BMS and a sealed aluminium alloy case, and it uses the same group-size footprint and terminal layout as a conventional 24V pack, which means the swap takes one technician about twenty minutes with no rewiring.

Cold mornings are where most battery brands lose customers. The same lightweight lithium battery keeps 90% of its rated cranking power at -20 ℃ and uses an integrated self-heating film to bring the cells up to working temperature before the first start of the day, so a tipper parked overnight at a northern quarry still fires on the first key turn. Because the chemistry holds voltage flat under load, cold cranking current stays far higher than a lead-acid pack of twice the weight, the starter motor spins faster and the engine control unit sees a stable 24V rail instead of the voltage sag that triggers fault codes on modern electronic engines.

• 60% Weight Saving: 12.5 kg replaces a 32 kg lead-acid pair, freeing payload and reducing front-axle load.
• 1200A Peak Cranking: three-second burst current covers large-displacement diesel engines up to 13 litres.
• Self-Heating Cold Start: reliable ignition and full cold cranking output down to -30 ℃ with a heating film controlled by the BMS.
• Weight Saving Without Compromise: the 60% weight saving does not reduce plate area or cranking reserve, because the LiFePO4 cells deliver their 1200A burst from a far smaller mass.
• 4000 Deep Cycles: more than 4000 charge and discharge cycles at 80% depth of discharge, about eight times the service life of a flooded battery.
• 200A Smart BMS: cell balancing, over-current, over-temperature and short-circuit protection with CAN, RS485 and Bluetooth telemetry.
• Sealed IP67 Case: dust-tight and water-immersion resistant, mounted anywhere on the frame without a ventilated box.
• Engine Starting Headroom: 1200A of cold cranking reserve keeps electronic engine management stable during cranking, even with a sleeper heater and telematics running.
• Drop-In Footprint: standard 24V group size, M8 terminals and the same hold-down points as the lead-acid pack it replaces.

The lightweight lithium battery is aimed at commercial fleets that measure cost per kilometre, and engine starting is only half of the calculation rather than cost per unit. Because the pack tolerates deep discharge without sulphation, drivers can run cab electronics, telematics and sleeper heaters overnight without the idle time that lead-acid packs force on long-haul routes. The weight saving is immediate, and so is the reduction in engine idling that starts to show on the fuel report within the first month. Typical installations include:

• Long-haul tractor units and rigid trucks with electronic engine management, where dependable engine starting decides whether the load leaves on time
• Tippers, mixers and mining haul trucks working in cold or dusty environments
• City buses and school buses with frequent stop-start duty cycles
• Cold-chain fleets that need dependable starting power next to refrigeration loads
• Municipal sweepers and utility vehicles with high auxiliary power demand

Q: How much weight does this lightweight lithium battery actually save?

A: A single pack weighs 12.5 kg against roughly 32 kg for the two 12V lead-acid batteries it replaces in a 24V system, so you remove about 20 kg per vehicle. On a fleet basis that weight saving is pure payload, and it is recovered on every single trip. On a forty-truck fleet that is close to 800 kg of payload recovered.

Q: Can it crank a diesel engine at -30 ℃ without a block heater?

A: Yes. The integrated heating film warms the cells before cranking, and the BMS releases full current once the pack reaches -10 ℃. Independent bench tests show first-turn starts at -30 ℃ on 12-litre engines, with cold cranking current held at the rated level throughout the burst.

Q: Do I need to change the alternator or charging system?

A: No. The pack accepts the standard 28.8V to 29.2V charging window produced by a normal truck alternator. The BMS simply limits current when the pack is cold and tapers the charge as it approaches full.

Q: How long will it last compared with the lead-acid set I run now?

A: The rated 4000 cycles at 80% depth of discharge translates to roughly six to eight years of daily fleet duty, against eighteen to twenty-four months for a flooded battery abused by overnight auxiliary loads.

Q: Is it safe to mount inside the cab or under a sleeper bunk?

A: The case is sealed to IP67 with a flame-retardant liner and no liquid electrolyte, so this lightweight lithium battery can be mounted in enclosed spaces where a vented lead-acid box would be prohibited.

Each lightweight lithium battery is shipped in a moulded EPE foam cradle inside a five-layer export carton, with terminal caps, a torque card and a QR code linked to the cell test report. Every unit passes a 100% end-of-line check for capacity, internal resistance, high-pot insulation and BMS communication before packing, and the shipment carries UN38.3, MSDS and CE documentation. Buyers receive a 24-month warranty covering capacity retention below 80% and a spare-parts commitment for BMS boards, so engine starting performance is protected for the whole service life. Tell us your engine displacement, alternator output and mounting space, and our engineers will confirm the correct configuration, cranking rating and weight saving for your duty cycle before the order is released.