Introduction

Against the global industry trend of cutting costs, boosting efficiency and pursuing green production in warehousing and logistics, the upgrading of electric forklift power systems has become inevitable. Plagued by cumbersome maintenance, short service life and heavy pollution, traditional lead-acid batteries are being phased out by an increasing number of factories, which opt to convert lead-acid batteries on their existing forklifts to lithium iron phosphate (LFP) batteries. The lithium battery retrofitting solution enables direct in-situ replacement without replacing the whole forklift. It drastically slashes long-term operation and maintenance expenses while complying with domestic and international environmental protection and export compliance standards, emerging as a mainstream upgrade solution for new and used warehousing equipment.

Against this industry backdrop, our company has completed a customized in-situ lead-acid-to-lithium conversion project for a STILL forklift. The matching lithium battery pack features identical dimensions and weight as the original factory lead-acid battery, requiring no modifications to the truck frame and offering direct compatibility with the electronic control system.

ⅠInherent Drawbacks of Traditional Lead-Acid Batteries

Cumbersome charging process: A full charging cycle takes 8 to 10 hours, and the battery must rest for another 6 hours before being put into service. Double-shift operations demand extra spare batteries for rotation.

Heavy maintenance workload: Regular electrolyte refilling and electrode plate cleaning are mandatory. Acid mist generated during charging corrodes the forklift body and contaminates stored goods in the warehouse.

Limited depth of discharge: The actual usable capacity is less than half of the rated capacity, resulting in noticeable power attenuation under high-load lifting conditions.

Short cycle life: Only around 1,200 charge-discharge cycles, requiring complete battery replacement every 2 to 3 years and leading to high overall long-term operating costs.

Strict charging site requirements: A separate well-ventilated and explosion-proof charging area is compulsory, occupying valuable usable storage space in warehouses.

II. Custom Same-Size Lithium Battery Replacement Solution

For the standard battery compartment dimension of 1028×855×784mm specified in drawings, we have developed an in-situ replacement LFP battery pack that matches the original lead-acid battery in both size and weight:

Precise dimensional matching: The lithium battery enclosure measures 1028×855×784mm, allowing direct hoisting and placement into the original battery compartment without frame cutting or modification.

Balanced vehicle counterweight: The total weight of the lithium battery assembly closely matches the original 1,863kg lead-acid unit, eliminating the need to add or remove forklift counterweights and guaranteeing stability during high-lift operations.

Seamless electronic control compatibility: The rated voltage of 83.2V perfectly fits the STILL 80V electronic control system, with CAN bus communication connected to the original dashboard for plug-and-play use.

Multi-layer safety protection: The IP65 dustproof and waterproof sealed enclosure integrates an intelligent Battery Management System (BMS) with comprehensive protection against overcharging, over-discharging, overcurrent, high temperature and short circuits. Cloud remote monitoring is supported to track battery level, temperature and operating status in real time.

High-speed fast charging design: Full charging takes only 3.5 hours. Fragmented top-up charging during lunch breaks or shift handovers is available, removing the need for rotating spare batteries.

III. Core Advantages of Lithium Battery Solution vs. Traditional Lead-Acid Batteries

Eliminates capital expenditure on spare batteries The entire charging and resting cycle of lead-acid batteries lasts over 14 hours, disallowing fragmented top-up charging. Multi-shift production thus requires a second set of batteries. Lithium batteries can regain substantial power through short intermittent charging, cutting hardware costs for extra batteries and labor costs for battery hoisting and replacement.

Zero daily maintenance to reduce labor costs Lead-acid batteries require dedicated staff for monthly water refilling, electrode cleaning and equalization maintenance. LFP batteries need no electrolyte refilling or equalization throughout their service life, with only one basic inspection required annually, delivering significant long-term savings on maintenance labor.

Ultra-long service life to amortize long-term procurement costs Lead-acid batteries only deliver 1,200 cycles and need replacement every 2–3 years. Our lithium battery pack achieves up to 6,000 stable cycles, serving reliably for 6–8 years. The one-time procurement cost can therefore be amortized across years of avoided battery replacements. In addition, lithium batteries boast a 95% charging efficiency with lower power loss than lead-acid counterparts, greatly reducing long-term electricity bills.

Safe and eco-friendly, releasing usable warehouse space Lead-acid batteries release corrosive acid mist during charging, posing risks of liquid leakage and equipment corrosion. Lithium iron phosphate batteries contain no acid liquid or harmful volatile fumes, removing the need for a dedicated explosion-proof charging room and freeing up valuable warehouse storage space. The sealed enclosure eliminates liquid leakage hazards, meeting domestic warehouse safety inspection standards and overseas environmental customs clearance requirements for exports.

IV. Summary of Retrofitting Solution

This lead-acid-to-lithium conversion case for the STILL forklift adopts a same-spec lithium replacement solution developed strictly in accordance with original factory battery drawings, requiring no alterations to the forklift body or electronic control system. All parameters of the complete solution are precisely matched to the truck’s working conditions.

Amid the prevailing industry shift from lead-acid to lithium batteries, this in-situ upgrade solution balances retrofitting costs and operational returns, with prominent advantages in charging efficiency, maintenance expenditure, service life, workshop safety and environmental performance. It serves as a mature upgrade plan for multi-shift warehousing enterprises to cut operating costs and optimize production workflows.

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