Installing lithium batteries to replace lead-acid batteries for electric forklifts: Things to know
Electric forklifts using lead-acid batteries over a long period often encounter issues such as long charging times, the need for regular maintenance, declining performance over time, and difficulty meeting multi-shift operation requirements.
Therefore, an increasing number of businesses are choosing Lithium batteries for electric forklifts as an alternative solution to improve operational efficiency and reduce vehicle downtime.
However, replacing a lead-acid battery with a Lithium battery is not as simple as picking a battery pack with the same voltage and installing it in the truck. The battery configuration must be compatible with each vehicle type and actual operating conditions.
Is it possible to replace a lead-acid battery with a Lithium battery?
Yes. Many types of electric forklifts can be converted from lead-acid to Lithium batteries.
However, before replacing, it is necessary to check:
- Vehicle system voltage.
- Required battery capacity.
- Current draw during operation and load lifting.
- Battery compartment dimensions.
- Weight and installation position.
- Terminal system and wiring.
- Existing charger.
- Business operational requirements.
Therefore, you should not select a battery based solely on 24V, 48V, or 72V specifications.
The Lithium battery replacement process for forklifts
A basic installation process consists of 5 steps:
1. Vehicle survey
Check the vehicle model, voltage, current battery capacity, battery compartment dimensions, and operational needs.
2. Defining battery configuration
Based on vehicle specifications and usage conditions, select the appropriate capacity, discharge current, BMS, and battery pack size.
3. Checking the charger
The charger must be compatible with the Lithium battery configuration. You should not assume that the current lead-acid battery charger can be used for Lithium batteries.
4. Installation and connection
The battery pack is placed into the correct position, securely fastened, and connected to the vehicle's electrical system according to the design.
5. Testing and commissioning
Check voltage, BMS, connections, charge/discharge capability, and perform a test run before official deployment.
When should a business switch to Lithium batteries?
Lithium batteries are particularly suitable for businesses that:
- Operate forklifts for many hours every day.
- Have multi-shift operation needs.
- Need to reduce vehicle downtime.
- Want to reduce battery maintenance tasks.
- Want better battery condition management.
- Have long-term forklift usage requirements.
The transition should be evaluated based on usage frequency, number of shifts, charging requirements, and total cost of ownership, rather than just comparing the initial purchase price between lead-acid and Lithium batteries.
CHY Battery – Lithium battery solutions for electric forklifts
CHY Battery provides Lithium-ion and LiFePO4 battery solutions for electric forklifts and industrial equipment.
Depending on the vehicle type, CHY Battery can provide consultation from:
Vehicle survey → configuration determination → battery pack design → BMS selection → charger check → installation → operational testing.
The goal is to select a battery pack tailored to the vehicle and actual usage needs, rather than using a one-size-fits-all configuration for all forklifts.
Are you using a lead-acid forklift?
Please provide the vehicle model, voltage, current battery capacity, and a photo of the battery compartment. CHY Battery can recommend a Lithium battery configuration suitable for your business's operational needs.
CHY Battery – Lithium battery solutions for electric forklifts.
