Practical operation and maintenance points of electrolyte ratio for forklift lead-acid batteries

Time：2025-07-07 10:27:03

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This article will provide a detailed introduction to the practical operation methods and maintenance points of the electrolyte ratio for forklift lead-acid batteries.

In the field of industrial handling, forklifts are indispensable important equipment, and lead-acid batteries, as the power core of forklifts, their performance directly affects the working efficiency and service life of forklifts. Electrolyte, as an important component of lead-acid batteries, a reasonable proportion and scientific maintenance are the keys to ensuring the normal operation of the battery. This article will provide a detailed introduction to the practical operation methods and maintenance points of the electrolyte ratio for forklift lead-acid batteries.
1. Practical Operation of Electrolyte Proportioning for Forklift Lead-Acid Batteries
(1) Composition and Function of the electrolyte
The electrolyte of forklift lead-acid batteries is mainly composed of sulfuric acid and distilled water mixed in a certain proportion. Sulfuric acid is a key substance involved in the electrochemical reaction of storage batteries, while distilled water serves to dilute sulfuric acid and regulate the density of the electrolyte. The appropriate electrolyte can ensure the smooth progress of chemical reactions inside the battery, thereby achieving the mutual conversion between electrical energy and chemical energy.
(2) Standards for electrolyte proportioning
There are certain differences in the electrolyte ratio of lead-acid batteries for forklifts of different specifications and application scenarios. Generally speaking, at 25℃, the density of the newly prepared electrolyte should be controlled at 1.28±0.01g/cm³. However, in actual operation, appropriate adjustments still need to be made according to the local climate conditions. For instance, in cold regions, to prevent the electrolyte from freezing, the density of the electrolyte can be appropriately increased to 1.29-1.30 g/cm³. In hot regions, to prevent the electrolyte water from evaporating too quickly due to excessively high temperatures, the density can be appropriately reduced to 1.27-1.28g /cm³.
(3) Practical steps for proportioning
Preparations: Prepare high-purity sulfuric acid, distilled water, acid-resistant containers, hydrometers, thermometers and protective equipment.
Diluting sulfuric acid: Sulfuric acid must be slowly poured into distilled water and constantly stirred with a glass rod to ensure it is fully diluted. It is absolutely forbidden to pour distilled water into sulfuric acid, as the dilution process of sulfuric acid releases a large amount of heat. If the sequence is reversed, it may cause the solution to splash and result in personal injury.
Measurement and adjustment: Use a hydrometer to measure the density of the electrolyte and simultaneously measure the temperature of the electrolyte. The density should be corrected according to the temperature. If the density does not meet the standard, it can be adjusted by adding distilled water or sulfuric acid.
Static cooling: The electrolyte with adjusted density needs to be left to stand for a period of time. After the temperature drops to room temperature, measure the density again to ensure it meets the requirements.
2. Key Points for Maintaining the Electrolyte of Lead-Acid Batteries in Forklifts
(1) Regularly check the electrolyte level
During the daily operation of forklifts, the electrolyte will gradually decrease due to evaporation and chemical reactions. Therefore, it is necessary to check the electrolyte level regularly, and it is generally recommended to do so every 1 to 2 weeks. When the liquid level is lower than the lowest mark, distilled water should be added in time. Note that only distilled water or dedicated lead-acid battery replenishment liquid can be added. It is strictly prohibited to add tap water or other unknown liquids to prevent impurities from entering the battery and affecting its performance and lifespan.
(2) Monitor the density of the electrolyte
Regular monitoring of the electrolyte density can help to promptly understand the charging and discharging status as well as the health condition of the battery. It is recommended to measure the density of the electrolyte at least once a week. If the density difference of the electrolyte in each individual cell of the battery exceeds 0.05g/cm³, it indicates that there may be a problem with the battery and further inspection and treatment are required.
(3) Keep the battery clean
Dust on the surface of the battery, electrolyte overflow and residue, etc. can cause self-discharge of the battery, affecting its performance. Therefore, the surface of the battery should be cleaned regularly. A damp cloth can be used to wipe it to remove dust and dirt from the electrolyte. At the same time, check whether the terminal posts and connecting wires of the battery are oxidized or loose. If there is oxidation, you can sand the terminal posts with sandpaper and apply a special battery protector to ensure good connection and reduce resistance.
(4) Avoid overdischarging and overcharging
Excessive discharge will cause sulfation of the battery plates, shortening their service life. Overcharging, on the other hand, will accelerate the evaporation of water in the electrolyte and intensify the aging of the plates. When using a forklift, pay attention to the battery level indicator. When the battery drops to around 20% to 30%, it should be charged in time. When charging, use the matching charger and operate strictly in accordance with the charger's instructions to avoid overcharging.
3. Frequently Asked Questions and Answers
What causes the electrolyte of forklift lead-acid batteries to be turbid?
Answer: Turbidity of the electrolyte may be caused by a variety of reasons. One reason is that the battery has been in use for too long, and the active substances on the plates fall off and enter the electrolyte. The second reason is that impurities have been mixed into the electrolyte, such as using unclean tools when adding the liquid; The third reason is that short circuits and other faults occur inside the battery, causing damage to the plates and the dissolution of substances into the electrolyte. If the electrolyte is found to be turbid, the battery should be inspected and repaired in time. If necessary, the electrolyte and plates should be replaced.
(2) How to deal with electrolyte leakage?
Answer: Once electrolyte leakage is detected, the first step is to take personal protective measures and wear protective equipment properly. Then, use materials with strong adsorption capacity to adsorb and collect the leaked electrolyte to prevent it from corroding the ground and other equipment. For areas contaminated by the electrolyte, they should be rinsed with a large amount of clean water and neutralized with alkaline substances to reduce acidity. Finally, the collected electrolyte and contaminated adsorption materials should be properly disposed of in accordance with the regulations for hazardous waste treatment.
(3) How to determine if the electrolyte needs to be replaced?
Answer: The electrolyte may need to be replaced when the following situations occur: First, the density of the electrolyte cannot be adjusted to the normal range; The second is that the color of the electrolyte is abnormally darker and accompanied by an unpleasant odor. Thirdly, the performance of the battery has significantly declined. For instance, if the usage time after charging is greatly shortened and other causes of failure are ruled out, it might be due to the failure of the electrolyte. In addition, if there are too many impurities in the electrolyte, affecting the normal operation of the battery, the electrolyte should also be replaced in a timely manner.
The proportioning and maintenance of the electrolyte in forklift lead-acid batteries is a meticulous and crucial task. Only by mastering the correct operation methods and maintenance points can the stable performance of the battery be ensured, its service life be prolonged, the usage cost of forklifts be reduced, and the efficient operation of industrial production be guaranteed.

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