This case study introduces a 76.8V 150Ah LiFePO₄ battery system designed as a complete scissor lift battery conversion kit and aerial lift battery upgrade solution for industrial AWP (Aerial Work Platform) applications.
It is engineered to fully replace traditional lead-acid battery systems used in scissor lifts, boom lifts, and aerial platforms, delivering higher efficiency, longer lifespan, and safer operation.
Project Background – Why Scissor Lift Battery Replacement Is Needed
In the global AWP industry, traditional lead-acid batteries are still widely used in scissor lifts and aerial work platforms. However, they create several operational limitations:
- Heavy battery weight reduces lifting efficiency
- Frequent replacement increases maintenance cost
- Limited discharge performance under hydraulic load
- Long charging time causes downtime
- Poor performance in low-temperature environments
To solve these issues, a scissor lift battery conversion kit based on LiFePO₄ technology is becoming the mainstream solution for aerial lift battery upgrade projects.
Solution – 76.8V 150Ah AWP Lithium Battery System
This lithium battery pack is designed specifically for scissor lift battery replacement and OEM AWP lithium battery upgrade applications.
Key Specifications
- Battery Chemistry: Lithium Iron Phosphate (LiFePO₄)
- Nominal Voltage: 76.8V (24S)
- Capacity: 150Ah
- Energy: 10.8kWh
- Cell Configuration: 24S1P (3.2V cells)
- Continuous Discharge: 1C
- Peak Discharge: 3C (10 seconds)
- Cycle Life: ≥3500 cycles @ 80% DOD
- Weight: 110–120kg
This system is fully compatible with most scissor lift and aerial lift platforms requiring a battery conversion kit upgrade.
Smart BMS for Aerial Lift Battery Upgrade Systems
The system integrates a high-voltage intelligent BMS designed for industrial scissor lift battery conversion kit applications.
Communication Interfaces
- CAN 2.0B (OEM integration)
- RS485 industrial protocol
- Bluetooth (optional mobile monitoring)
Protection Functions
- Over-voltage & under-voltage protection
- Over-current & short-circuit protection
- High/low temperature protection
- SOC real-time monitoring
- SOH battery health prediction
- Active cell balancing system
Optional Features
- LCD display panel
- Mobile APP monitoring
- Audible alarm system
Mechanical Design for Scissor Lift Battery Replacement
This AWP lithium battery system is designed for harsh construction and rental environments.
- Industrial-grade metal enclosure
- IP65 waterproof and dustproof rating
- Built-in fuse + emergency shut-off switch
- Anti-reverse connection charging port
- Heavy-duty connectors for high current load
- Portable design with handle and wheels
Dimensions: 700 × 500 × 300 mm (customizable for OEM scissor lift battery conversion kit projects)
Performance for Aerial Work Platforms
Charging & Discharging Parameters
- Max Charging Current: 75A (0.5C)
- Continuous Discharge: 150A
- Peak Discharge: 300A (10 seconds)
- Charging Temperature: 0°C ~ 55°C
- Discharging Temperature: -20°C ~ 60°C
- Optional Heating System: Supports low-temperature operation down to -20°C
This ensures stable output for hydraulic lifting systems used in aerial work platforms.
Advantages of This Scissor Lift Battery Conversion Kit
1. Direct Lead-Acid Replacement
This system is a plug-and-play scissor lift battery replacement solution, requiring no complex modification for most AWP equipment.
2. Lightweight Design
- 40% weight reduction vs lead-acid
- 30% space saving
- Improved machine efficiency and mobility
3. Long Cycle Life
- ≥3500 cycles
- 3–4 times longer lifespan than lead-acid
- Reduced replacement frequency
4. High Power Output for Aerial Lift Systems
- Stable 1C continuous discharge
- 3C peak power support
- Ideal for hydraulic lifting operations
5. Smart Aerial Lift Battery Upgrade System
- Real-time SOC/SOH monitoring
- CAN/RS485 communication for OEM integration
- Reduced maintenance cost and downtime
6. Modular Expansion
- Supports parallel connection
- Expandable up to 21.6kWh
- Flexible for different scissor lift models
Application Scenarios
This scissor lift battery conversion kit / AWP lithium battery system is widely used in:
- Electric scissor lifts
- Aerial work platforms (AWP)
- Boom lifts & cherry pickers
- Warehouse maintenance platforms
- Industrial lifting equipment
- Construction access systems
Technical Value – Why This Aerial Lift Battery Upgrade Solution Stands Out
Compared with traditional battery systems, this solution provides:
- Higher uptime for rental fleets
- Lower total cost of ownership (TCO)
- Faster charging cycles
- Safer lithium iron phosphate chemistry
- Reduced maintenance workload
- Improved operational efficiency
It is a future-ready aerial lift battery upgrade solution for global OEM manufacturers and equipment operators.
Conclusion
The 76.8V 150Ah LiFePO₄ system is a complete scissor lift battery conversion kit designed for modern aerial lift battery upgrade requirements.
As a high-performance AWP lithium battery solution, it delivers longer lifespan, stronger power output, and significantly lower operating costs compared to traditional lead-acid batteries.
It is the ideal upgrade path for OEMs, rental companies, and industrial users seeking reliable scissor lift battery replacement solutions.
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