Jungheinrich Forklift truck EFG110 25.6V 560Ah LiFePO4 UN 38.3

　　How to choose the matching lithium batteries for the Yonghuanli Forklift EFG110? Ventura LFP5608S2P Comprehensive Guide

　　How to choose the matching lithium batteries for the Yonghuanli Forklift EFG110? Ventura LFP5608S2P Comprehensive Configuration Guide

　　If you want to replace the Eternal Force EFG110 with a set of lithium-ion batteries, you'll find the parameters are more complex than you might have imagined—voltage, capacity, charger compatibility, dimensions, and export documentation. A single oversight in any of these areas could delay deployment.Instead of worrying about the specification sheet, let's directly start with a solution that has already been implemented: VENTURA's lithium iron phosphate battery pack for this vehicle model, model LFP5608S2P. Below, we will use a breakdown-style Q&A to clarify the selection, assembly, charging, leasing, export, and after-sales service processes.

　　What exactly is the lithium battery specification compatible with the Eternal Force EFG110?

　　The nameplate parameters of this battery can be summarized as follows: total power 14.336 kWh, nominal voltage 25.6 V, rated capacity 560 Ah, weight 480 kg, and external dimensions 830 × 327 × 627 mm.At first glance, they may just appear as a set of numbers, but when applied to real-world scenarios, each item holds its own significance. The 25.6V platform precisely falls within the electrical window of the Yonghengli 24V vehicle series, eliminating the need for additional boost or step-down modules, and offering higher compatibility with the original vehicle's motor and controller.With a capacity of 560Ah, compared to the common lead-acid batteries for this model—such as the 5PzS575 (24V/575Ah), 5PzS600 (24V/600Ah), or even 5PzS625 (24V/625Ah)—the actual usable energy is nearly identical. However, lithium battery systems show significant differences in discharge depth and voltage platform stability, which will be elaborated on later.With a self-weight of 480 kg, it is significantly lighter than lead-acid battery packs of the same capacity, which has positive effects on the forklift's bridge load capacity, tire wear, and energy consumption.The installation dimensions of 830×327×627mm are precisely molded according to the battery compartment of the Yonghengli EFG110. After insertion, the gaps on all four sides are uniform. Once the locking plate is tightened, it is complete—no need for beam cutting or padding blocks.

　　Internal Electrical Structure: How does 8 series 2 parallel form 25.6V 560Ah?

　　Many friends, when they see the technical parameters, will ask how many cells are actually used in 8 series 2 parallel, and what the parameters of each cell are. This battery pack internally integrates a total of 16 lithium iron phosphate large square cells, using an 8 series 2 parallel topology: first, 2 cells are connected in parallel to form a group, resulting in a basic unit of 3.2V/560Ah, then 8 such units are connected in series to achieve 25.6V/560Ah. The nominal voltage of each single cell is 3.2V, with a charging limit voltage of 3.65V and a discharge cutoff voltage of 2.5V. The advantage of this design is that the series-parallel logic is simple, the electrical connection points are few, internal resistance is lower, and heat generation is more uniform. The charging voltage of the battery pack is set at 29.2V, which exactly corresponds to 8 series×3.65V. Unlike common lead-acid chargers, the selection of the charging station needs to be considered independently.

　　These cells come from the major domestic automotive-grade power cell manufacturers—CATL, EVE, CALB, Lishen, etc. Depending on the batch and supply situation, VENTURA selects A-grade cells of the same brand and specification according to automotive-grade material standards. They are not industrial-grade or recycled cells. Each cell comes with a complete traceability code, and factory internal resistance and capacity deviation are controlled within a very narrow range, laying the foundation for consistency in subsequent PACK assembly.

　　Charging Station and Distribution: How to implement AC380V/DC29.2V/150A?

　　To fully utilize the fast-charging capability and cycle life of lithium iron phosphate, the selection of the charger is often more easily overlooked than the battery itself. For the LFP5608S2P battery pack, VENTURA recommends an ideal charging station with the following parameters: AC input 380V, DC output 29.2V/150A. The constant voltage of 29.2V ensures that 8 series cells are not overcharged, and 150A current corresponds to approximately 0.27C for the 560Ah capacity, balancing charging speed and cell temperature rise. During actual charging, the battery can be charged from 20% SOC to full in a controllable duration, suitable for fragmented charging during lunch breaks or shift changes. If the user's site only has AC220V power, a slightly lower-power charger can be used, but the charging time will be correspondingly longer. This can be determined according to daily working hours and shifts. VENTURA's technical support personnel usually conduct on-site surveys of the distribution capacity and then provide a matching solution.

　　Another detail worth noting: the voltage curve of a lead-acid charger does not completely match lithium iron phosphate. If the original lead-acid charger is used directly to charge lithium batteries, it may trigger overvoltage protection prematurely or fail to fully charge the battery, which can cause hidden damage to the cells over time. Therefore, when switching from lead-acid to lithium, it is relatively safer to configure a lithium-dedicated charging station in one step.

　　Why are more and more people at sites switching from lead-acid to lithium iron phosphate? This goes back to the actual conditions of warehousing, logistics, express delivery, and port terminals. Lead-acid batteries have been used in forklifts for decades. Their technology is mature and their purchase prices are low, but their drawbacks are obvious: a full charge usually takes 8-10 hours, plus water replenishment, acid mist corrosion protection, regular balanced charging, and deep cycle life typically ranges from several hundred to over a thousand cycles. Sites with two or three shifts often need to have battery replacements, with dedicated charging rooms and high maintenance labor costs. The benefits of the lithium iron phosphate route address these pain points. Deep cycle cycles exceed 4,500 cycles, meaning the cost per charge and discharge over the entire lifecycle is actually lower. Supports charging during periods; plugging in during lunch breaks or unloading for a while can significantly recharge the SOC, reducing the number of spare batteries and even allowing a single battery to run all day. No acid mist, no need for water refilling, no hydrogen generation, making it cleaner and safer to use in sealed warehouses, especially friendly for food and pharmaceutical scenarios. At the same time, the voltage platform remains flat for most discharge intervals, forklift power output is linear, and lifting speed is stable, making operation smoother than the weak mid-to-late stages of lead-acid batteries. VENTURA itself has dual-track production capabilities for lead-acid and lithium batteries. Because both systems have been manufactured for a long time, it is clearer which solution is more cost-effective in different scenarios. Some customers still use lead-acid on some old vehicles, while newly purchased or high-frequency vehicles are equipped with lithium batteries, complementing each other, resulting in a stable switching pace. Why has VENTURA become the preferred choice for Jungheinrich OEMs? First, let's clarify a concept: OEM matching is not simply about stuffing batteries into the vehicle body, but about achieving original vehicle development-level matching across multiple dimensions such as electrical interfaces, communication protocols, installation structure, center of gravity distribution, and thermal management. VENTURA has long provided original solutions for Jungheinrich counterbalance forklifts, reach trucks, pallet trucks, forklifts, AGVs, and more. The battery pack used in the EFG110 is customized based on Jungheinrich's original design drawings and interface definitions. The battery connectors, vent positions, and locking methods all follow factory specifications, ensuring no modifications to the vehicle body after installation. From a product structure perspective, the battery pack uses an integrated sheet metal shell with a built-in shock-resistant buffer layer, laser welding aluminum busbar for pole connections, and modules separated by insulated pressure-resistant partitions. The self-developed BMS is installed inside the battery, monitoring the voltage and temperature of each cell in real time, providing multiple protections such as overcharge, over-discharge, short circuit, and reverse connection. It can also communicate with instrument panels on certain models via the CAN bus, directly displaying battery level and fault codes on the screen. This level of integration requires a thorough understanding of the vehicle's electrical architecture, not simply stacking capacity.

　　Looking further back, VENTURA's accumulation in lithium iron phosphate PACK system integration is widely recognized in the domestic forklift industry: it ranks among the top tier of forklift lithium-ion battery manufacturers in Guangdong Province, consistently ranks among the top three nationwide in overall strength, with annual export revenue exceeding 600 million yuan, covering models ranging from 1 ton to 10 ton heavy-duty forklifts, covering both high-voltage and low-voltage platforms. The manufacturing team is familiar with the electrical characteristics of European and Japanese vehicles, and has long-term supply records for imported brands such as Jungheinrich, Linde, Toyota, BT, Komatsu, Mitsubishi, Lizhiyou, Coron, Yale, Doosan, STILL, Hyster, and CROWN. This is also why many overseas customers choose VENTURA as their designated supplier.

　　How can you ensure that the 16 cells can still run side by side after long use?

　　Cell consistency is key to the long lifespan of lithium batteries. VENTURA's approach can be broken down into several steps: First, cell admission, selecting only automotive power battery-grade A cells. After entering the factory, all tests are conducted for open-circuit voltage, AC internal resistance, and capacity, with voltage and resistance levels classified. Within the same battery pack, the voltage difference and resistance difference of cells are much smaller than industry standards. Second, in the PACK section, the busbar uses laser welding to ensure consistent resistance and no false solder joints. The BMS features passive balancing, micro-discharging and balancing cells with higher voltage at the end of the charge. Over the years, the voltage difference across the entire cell group remains small, preventing premature degradation of individual cells that drag down the entire group. Additionally, the case has excellent heat dissipation design, ensuring uniform cell temperature and synchronized aging speed.

　　With so many countries exported, how can certification documents be cleared one by one?

　　When exporting forklift lithium batteries, what really slows down progress is often certification and transportation documentation. VENTURA has established a relatively complete basic documentation system in this area, covering the full range of models, and issuing corresponding reports based on tracking number and destination during shipment. Common examples include: UN38.3 test report, which forms the foundation for lithium battery transportation safety; MSDS chemical safety technical specification; DGM transport hazard assessment report, covering sea, road, and air transport modes; Hazard characteristic classification identification report, commonly known as hazardous special certificate; Use of identification result sheets (hazardous package certificates) for outbound dangerous goods transport to ensure packaging complies with international transport regulations; In addition, there are safety certifications such as CE and UL. Orders to countries such as Vietnam, Russia, Kazakhstan, Turkey, and Nigeria usually clear customs smoothly due to complete documentation and standardized labeling. In North America and Europe, the completeness of certification directly determines whether products can enter local distribution. VENTURA's UL and CE coverage has greatly relieved distributors of concerns.

　　How many tonnage and types of vehicles can it cover?

　　VENTURA provides more than just the EFG110 battery for Still's forklift series. From lightweight pallet trucks and stackers to heavier counterbalance forklifts and reach trucks, you can find corresponding lithium iron phosphate models. The voltage platforms cover 24V, 48V, 80V, 96V, and even higher, with capacities ranging from over a hundred amp-hours to more than a thousand amp-hours, supporting a variety of heavy-duty forklifts from 1 ton to 10 tons. High-voltage, high-power models require more advanced cell grouping technology and insulation protection, while low-voltage models rely more on BMS stability and thermal management during high-current discharges. VENTURA delivers both high and low voltage lines in bulk, which in turn promotes the transfer of technical experience, making control logic on the low-voltage platform more rigorous and cost structures on the high-voltage platform more optimized.

　　The transition of Still's EFG110 from lead-acid to lithium iron phosphate is no longer an isolated case; it represents a small but concrete part of the electrification of logistics equipment. Whether battery model specifications are accurately matched tests PACK companies' ability to use automotive-grade cells, their adherence to OEM standards, and their capability to meet global customer demands. For VENTURA, the LFP5608S2P model is just one of many solutions, but it happens to reflect the whole system's operation—from cell sorting to module welding, from BMS strategy development to charge curve calibration, from issuing dangerous goods documentation to real-time responses from overseas agents. Ultimately, battery selection comes down to the integrated support of both people and technology.