Maintenance skills and common maintenance items for forklift lead-acid batteries

Time：2025-07-05 11:07:10

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Mastering the maintenance skills of lead-acid batteries for forklifts and understanding common maintenance items are crucial for ensuring the normal operation of forklifts and reducing operating costs.

In the field of industrial handling, forklifts are indispensable important equipment, and forklift lead-acid batteries are the key to forklifts, providing them with continuous and stable power. However, after long-term use, various problems are inevitable for the battery. Mastering the maintenance skills of lead-acid batteries for forklifts and understanding common maintenance items are crucial for ensuring the normal operation of forklifts and reducing operating costs.
1. Common Maintenance Items for Forklift Lead-Acid Batteries
(1) Electrolyte replenishment
During the operation of lead-acid batteries, the moisture in the electrolyte gradually decreases due to electrolysis and evaporation, causing the electrolyte level to drop. When the liquid level drops below the minimum mark, it is necessary to replenish the electrolyte. Generally speaking, distilled water or dedicated lead-acid battery replenishment liquid should be added. Tap water or other impure water must not be added, as the impurities in tap water can affect the performance and lifespan of the battery.
(2) Plate vulcanization repair
Plate sulfation is one of the common faults of forklift lead-acid batteries. Sulfation of the plates will reduce the capacity of the battery and make charging difficult. The main causes of sulfation of the plates include long-term insufficient charging of the battery and too low electrolyte level, etc. When sulfation of the plates is detected, it can be repaired by charging with a small current for a long time, or by using dedicated repair equipment for treatment.
(3) Repair of damaged shells
During the operation of forklifts, the battery casing may be damaged due to collisions or other reasons. If the damage to the shell is not severe, it can be repaired using a dedicated plastic welding tool. If the damage is severe, to ensure safety and performance, a new battery casing needs to be replaced.
2. Maintenance Tips for Forklift Lead-Acid Batteries
(1) Regular inspection and maintenance
Regular inspection of lead-acid batteries in forklifts is the key to preventing faults. The inspection contents include the height of the electrolyte level, voltage, temperature, etc. It is generally recommended to check the electrolyte level once a week and conduct a comprehensive voltage and temperature test once a month. Through regular inspections, potential problems can be detected in a timely manner and dealt with in advance to prevent the expansion of faults.
(2) Correct charging method
The correct charging method is crucial for extending the lifespan of the battery. Before charging, the height of the electrolyte level should be checked first to ensure it meets the requirements. When charging, use a charger that matches the battery's specifications to avoid overcharging or undercharging. Under normal circumstances, the charging current should not be too large and the charging time should not be too long. When the battery is fully charged, charging should be stopped in time to prevent problems such as battery overheating and plate aging caused by overcharging.
(3) Fault Diagnosis skills
When the lead-acid battery of a forklift malfunctions, accurate fault diagnosis is the prerequisite for maintenance. The cause of the fault can be determined by observing the appearance of the battery, measuring the voltage and current, and checking the state of the electrolyte, etc. For instance, if the battery casing gets hot, it might be due to excessive charging current or an internal short circuit. If the voltage is too low and charging is impossible, it might be due to sulfation of the plates or an open circuit.
3. Frequently Asked Questions and Answers
(1) What should I do if the lead-acid battery of a forklift cannot be charged?
When encountering a situation where the lead-acid battery of a forklift cannot be charged, the first step is to check whether the charger is working properly, including the power connection of the charger and the status of the indicator light, etc. If the charger is functioning properly, then check whether the connection wires of the battery are loose or oxidized. If there are any problems, clean and tighten them in time. Then, measure the voltage of the battery. If the voltage is too low, it might be due to severe sulfation of the plates or an internal open circuit. At this point, professional equipment should be used for detection and repair, or the battery should be considered for replacement.
(2) How to determine whether the lead-acid battery of a forklift needs to be replaced?
To determine whether the lead-acid battery of a forklift needs to be replaced, multiple aspects can be considered. If the capacity of the battery drops significantly, even after being fully charged, the working time of the forklift is greatly shortened, and it still cannot return to the normal level after repair, then it is necessary to consider replacing it. In addition, when the battery suffers from severe damage to the casing, severe deformation of the plates or short circuits and other irreparable faults, a new battery should also be replaced in a timely manner to ensure the normal operation and safe use of the forklift.
(3) What should be noted when using lead-acid batteries for forklifts in winter?
The low temperature in winter will have a certain impact on the performance of lead-acid batteries in forklifts. When using it in winter, the first thing to pay attention to is to replenish the electrolyte in time and maintain an appropriate liquid level height to prevent the electrolyte from freezing due to low temperature and damaging the battery. Secondly, try to park the forklift indoors or in a warmer environment to avoid leaving the battery at low temperatures for a long time. In terms of charging, since low temperatures can reduce the battery's charging acceptance capacity, the charging time can be appropriately extended to ensure that the battery is fully charged.
In conclusion, mastering the maintenance skills of lead-acid batteries for forklifts, being familiar with common maintenance items and problem-solving methods can effectively enhance the operational efficiency of forklifts and reduce the operating costs of enterprises. At the same time, regular maintenance and correct usage methods can also significantly extend the service life of the battery, providing a strong guarantee for the production and operation of enterprises.

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