LITHIUM BATTERY INSTALLATION REPLACING LEAD-ACID BATTERY FOR 2.5-TON FORKLIFT
An effective upgrade solution for electric forklifts using lead-acid batteries
During the operation of electric forklifts, traditional lead-acid batteries often develop various issues over time, such as decreased performance, long charging times, the need for periodic maintenance, and, for certain types, the requirement to top up water.
To improve operational efficiency and reduce long-term costs, CHY Battery has completed a project to replace the lead-acid battery system with a Lithium-ion battery for a 2.5-ton forklift.
This is a suitable solution for businesses currently using electric forklifts that want to upgrade their power system without replacing the entire vehicle.
1. Status of the forklift before conversion
The 2.5-ton Komatsu forklift is using a traditional lead-acid battery set.
Based on actual images, the battery set has been in use for some time and shows signs of surface dirt, oxidation, and deterioration. These are common issues for lead-acid battery systems after a period of operation in industrial environments.
Additionally, lead-acid batteries require periodic inspection and maintenance to maintain stable operational capacity.
The chosen solution is to replace the lead-acid battery system with a Lithium-ion battery pack designed specifically for the forklift.
2. Survey and design of the Lithium-ion battery pack
Before proceeding with installation, CHY Battery conducts an on-site survey of the forklift, the battery compartment, and the existing electrical system.
Factors considered include:
- Dimensions and space for battery pack installation.
- The vehicle's operating voltage.
- Usage requirements and operating time.
- Compatibility with the charging system.
- Power connection points.
- Battery control and protection system.
- Environmental conditions and frequency of operation.
Based on survey data, the Lithium-ion battery pack is designed according to the actual requirements of the forklift and the customer's usage needs.
Designing specifically for each vehicle model ensures the battery pack fits perfectly within the existing battery compartment while meeting all operational and safety requirements.
3. Removal of the old lead-acid battery
The first step in the conversion process is to remove the lead-acid battery currently in use.
The old system is inspected prior to removal to determine the condition of the wiring, terminals, connection points, and related components.
This inspection helps technicians accurately determine the connection plan and minimize issues that may arise during the installation of the new battery system.
4. Installation of the Lithium-ion battery for the forklift
After completing the removal of the old battery, the Lithium-ion battery pack is placed into the forklift's battery compartment.
The battery system is arranged neatly, with power and signal cables organized to fit the space inside the compartment.
One of the critical components of the system is the BMS (Battery Management System), which is responsible for monitoring and controlling the battery pack's operating parameters.
5. System completion and operational testing
After installation, technicians perform a full system check before putting the forklift into operation.
Items tested include:
- Check power connections.
- Check terminals and wiring.
- Check the BMS system.
- Check battery pack voltage.
- Check charging capability.
- Check power supply to the vehicle.
- Check forklift functionality.
- Check the system's safety functions.
Once completed, the vehicle undergoes test runs to evaluate the battery pack's response under real-world usage conditions.
6. Why switch from lead-acid to Lithium-ion batteries?
Replacing lead-acid batteries with Lithium-ion batteries offers many benefits for businesses that use forklifts frequently.
Flexible charging and usage time
Lithium-ion batteries offer fast charging capabilities and are suitable for operations that require multiple shifts per day.
Businesses can proactively plan charging schedules to suit their actual operational requirements.
No water maintenance required like lead-acid batteries
One of the notable advantages of Lithium-ion batteries is that they do not require periodic water topping, unlike traditional lead-acid batteries.
This reduces maintenance work and limits issues that may arise during use.
Stable performance
Lithium-ion batteries can maintain stable performance during operation.
This is particularly important for forklifts working regularly in factories, warehouses, and production areas.
Long lifespan
With a design using high-quality Lithium-ion cells and a BMS battery management system, the battery pack can achieve a longer lifespan than many traditional lead-acid systems.
CHY Battery focuses on using high-quality cells and designing battery packs tailored to the actual needs of each forklift model.
Reduced long-term operating costs
When considering the total cost of ownership, businesses should look beyond the initial purchase price to include electricity costs, maintenance, labor, and downtime for charging or repairs.
Switching to Lithium-ion can help businesses optimize these costs over long-term use.
7. Lithium-ion solutions for every forklift model
Not all forklifts use the same type of battery.
Therefore, CHY Battery does not apply a single configuration to every vehicle, but rather performs surveying – calculation – design – installation based on each specific vehicle type and operational need.
Information considered includes:
Vehicle model → load capacity → voltage → capacity → battery compartment dimensions → operational needs → charging system → Lithium-ion battery configuration.
This approach ensures the battery pack is better suited to the vehicle and the customer's actual usage conditions.
8. CHY Battery – Lithium-ion battery solutions for forklifts
With experience in designing and assembling Lithium-ion battery packs, CHY Battery provides conversion solutions from lead-acid to Lithium-ion for many types of electric forklifts.
We focus on solutions tailored to each specific need, from vehicle surveying, cell configuration selection, and pack design to BMS integration, installation, and operational testing.
If you have a requirement, CHY Battery always has a solution.
If your business is using electric forklifts and experiencing issues with lead-acid batteries such as long charging times, frequent maintenance needs, degraded performance, or high operating costs, contact CHY Battery for advice on a suitable conversion to Lithium-ion batteries.
CHY Battery – Lithium-ion battery solutions for forklifts
CHY Trading and Service Co., Ltd.
📞 Hotline: 0983 925 952
📧 Email: chybatteries@gmail.com
Survey – Design – Installation – Lithium-ion battery conversion for electric forklifts.
