For forklift rental companies, lead-acid battery maintenance can quickly become a daily burden. Regular watering, acid cleaning, long charging time, and battery performance decline all increase labor costs and reduce equipment availability.
In this case, TAVO Battery completed a lithium battery upgrade for three Jungheinrich EFG 540K electric forklifts. The original lead-acid batteries were removed and replaced with TAVO lithium battery systems designed for rental fleet operations.
Project Overview
| Forklift Model | Jungheinrich EFG 540K |
| Battery Type | LiFePO4 Forklift Lithium Battery |
| Battery Voltage | 83.2V |
| Battery Capacity | 606Ah |
| Connector | REMA320 |
| Application | Rental Forklift Fleet |
Why Upgrade Rental Forklifts to Lithium Batteries?
Rental forklifts usually face higher usage frequency than privately owned equipment. Different operators may use the same forklift, and maintenance is not always handled consistently. Therefore, lead-acid batteries often create extra work for rental companies.
By upgrading to TAVO lithium batteries, the customer can reduce routine maintenance tasks such as watering, acid cleaning, and equalization charging. This makes the forklift easier to manage and more suitable for rental operations.
Battery Removal and Lithium Battery Installation
The upgrade started by removing the original lead-acid batteries from the three Jungheinrich forklifts. After that, the TAVO lithium battery packs were installed into the battery compartments.
The 83.2V 606Ah lithium battery was selected according to the forklift model, working requirements, and battery compartment space. The battery also used a REMA320 connector to match the vehicle connection requirements.
You can view the product details here:
Jungheinrich EFG 540K Lithium Battery Forklift 83.2V 606Ah.
Dashboard Wiring and Display Installation
After the battery installation, the team deployed the display wiring inside the forklift body. The wiring was routed through the internal structure and fixed with cable ties to prevent exposure, movement, or damage during daily operation.
Then, the battery display supplied with the lithium battery was installed. The display angle was adjusted based on the driver’s operating habits, making it easier to check battery status during use.
Remote Battery Monitoring
One practical advantage of this lithium battery upgrade is battery status monitoring. Operators or fleet managers can scan the code with a mobile phone to check battery information remotely.
For rental forklift customers, this function is especially useful. It helps improve fleet management and allows users to understand battery status without opening the battery compartment or relying only on manual inspection.
Charging and Function Testing
After installation, the team connected the dedicated lithium battery charger and tested the charging function. The display was carefully checked to confirm that charging data appeared normally.
Once charging was confirmed, the vehicle discharge connector was connected. The forklift was powered on through the display switch, and all main vehicle functions were tested.
Only after confirming that lifting, driving, display, charging, and discharge functions were normal was the upgrade considered complete.
Key Benefits of the TAVO Lithium Battery Upgrade
- Maintenance-free operation: No watering, no acid cleaning, and no frequent manual maintenance.
- Better fleet management: Battery status can be checked through mobile scanning and display monitoring.
- Cleaner operation: Lithium batteries avoid acid leakage risks common in lead-acid systems.
- Improved rental suitability: Less maintenance makes the forklift easier to manage across different users.
- Dedicated charging: The system works with a matched lithium battery charger for safer charging performance.
Conclusion
This Jungheinrich EFG 540K lithium battery upgrade shows how rental forklift fleets can reduce maintenance work and improve daily battery management. By replacing traditional lead-acid batteries with an 83.2V 606Ah TAVO lithium battery, the customer gained a cleaner, easier, and more practical power solution.
For companies operating Jungheinrich forklifts or rental fleets, a correctly matched lithium battery upgrade can help reduce downtime, simplify maintenance, and improve long-term equipment efficiency.