Operation preparations for lead-acid batteries used in forklifts before long-term idleness

Time：2025-07-08 09:42:38

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Therefore, it is extremely necessary to master the operational preparation knowledge for lead-acid batteries used in forklifts before they are idle for a long time.

In the daily use of forklifts, lead-acid batteries play a crucial role, providing strong power support for forklifts. However, when forklifts need to be idle for a long time due to seasonal shutdowns, project completions, or other reasons, if the lead-acid batteries are not properly prepared for operation, it may lead to a decline in battery performance, a shortened lifespan, or even an inability to be used normally, causing unnecessary losses to the enterprise. Therefore, it is extremely necessary to master the operational preparation knowledge for lead-acid batteries used in forklifts before they are idle for a long time.
Conduct a comprehensive inspection of the battery condition
Before the lead-acid battery of a forklift is left idle for a long time, a comprehensive inspection of its condition is the top priority. This stage can promptly identify problems with the battery and provide a basis for subsequent handling.
When inspecting the appearance, carefully check whether the battery casing has any cracks, deformations or other conditions. If cracks appear on the casing, the electrolyte may leak, which not only corrodes the surrounding components but also affects the performance of the battery. At the same time, it is necessary to check whether there is any corrosion on the electrode terminals. Corrosion can lead to poor contact and affect the conduction of current. The terminals can be wiped with a clean cloth. If the corrosion is severe, an appropriate amount of vaseline can be applied for protection.
Secondly, it is necessary to check the battery's charge. A dedicated battery tester can be used to measure the voltage and capacity of the battery. If the voltage is lower than the standard value, it indicates that the battery power is insufficient and it needs to be charged in time. If the battery capacity drops significantly to less than 70% of its rated capacity, it is necessary to consider whether to carry out maintenance or replacement.
In addition, the liquid level of the electrolyte should also be checked. For maintainable lead-acid batteries, the electrolyte level should be maintained at 10-15mm above the plates. If the liquid level is too low, it will cause the plates to be exposed to the air, accelerating their oxidation and corrosion. At this point, distilled water should be added to the appropriate liquid level. Note that tap water or electrolyte should not be added to avoid affecting the performance of the battery.
Thoroughly clean the battery
Cleaning the battery is an indispensable operation step before long-term idleness. A clean environment can reduce the corrosion and damage to the battery.
First, wipe the battery's casing and electrode terminals with a damp cloth to remove surface dust, oil stains and other impurities. For stubborn stains that are hard to remove, you can wipe them with baking soda water. Baking soda water has certain decontamination and neutralization effects on acidic substances. However, after wiping, use clean water to wipe off any remaining baking soda water to avoid corroding the battery.
Secondly, the electrode terminals and connecting cables should be cleaned. The terminal posts and cable joints can be gently sanded with fine sandpaper to remove the surface oxide layer and corrosion products, ensuring a good connection. After grinding, wipe it clean with a clean cloth and then apply a layer of vaseline to prevent further oxidation and corrosion.
Reasonable charging and battery maintenance
Long-term undercharging of lead-acid batteries can lead to sulfation of the plates, which is one of the main reasons affecting the battery's lifespan. Therefore, before long-term idleness, it is necessary to charge the battery reasonably and maintain an appropriate level of power.
When charging, use a charger that matches the battery and operate according to the charger's instructions. During the charging process, pay close attention to the temperature of the battery. If the temperature is too high (exceeding 45℃), charging should be suspended. Wait until the temperature drops to the normal range before resuming. Under normal circumstances, when the battery voltage reaches the rated voltage and the electrolyte starts to bubble, it indicates that the battery is fully charged.
After being fully charged, do not leave the battery idle immediately. Instead, let it stand for 1 to 2 hours to allow the electrolyte to mix thoroughly. At this point, the battery's charge should be maintained at around 80% to 90%. This charge state can not only prevent sulfation of the plates but also reduce the self-discharge loss of the battery.
Store the battery correctly
Choosing an appropriate storage environment and method can effectively protect the battery from damage during long-term idleness.
The storage location should be chosen in a dry, well-ventilated and cool place, avoiding direct sunlight and high-temperature environments. At the same time, keep away from fire sources and flammable and explosive items to prevent safety accidents. When storing, the battery should be placed steadily to avoid tilting or inverting it to prevent electrolyte leakage.
For maintainable storage batteries, the level of the electrolyte should be checked regularly during storage. If the level is too low, distilled water should be added in time. For maintenance-free batteries, although no electrolyte needs to be added, their appearance and voltage should still be inspected regularly.
In addition, the battery should be disconnected from the forklift, and the cables on the electrode terminals should be removed to prevent the battery from having a weak current output during idle periods, which could lead to power consumption. When removing cables, the negative cable should be removed first, followed by the positive one. The process is reversed during installation to prevent short circuits.
Frequently Asked Questions and Answers
Question: What should be done if the lead-acid battery of a forklift drops significantly after being idle for a long time?
Answer: When the lead-acid battery of a forklift has been idle for a long time and its power significantly drops, the first step is to check whether the battery is damaged, such as cracks in the casing or corrosion of the plates. If there is no damage, you can try slow charging with a dedicated charger. The charging time may be longer than the normal charging time. During the charging process, pay close attention to the status of the battery. If any abnormal situation occurs, stop charging immediately. If the battery power still cannot be restored after charging, it may be due to severe sulfation of the plates, and professional maintenance or replacement is required.
Question: Do lead-acid batteries that have been idle for a long time need to be charged regularly during storage?
Yes, lead-acid batteries that have been idle for a long time need to be charged regularly during storage. Generally speaking, the battery should be recharged once every 1 to 2 months to keep its power level at around 80% to 90%. This can effectively prevent sulfation of the plates and extend the service life of the battery. When charging, operate in accordance with the normal charging method to avoid overcharging.
In conclusion, the operation preparation for lead-acid batteries used in forklifts before they are idle for a long time is a meticulous and important task, covering multiple links such as inspection, cleaning, charging and storage. Only by doing these preparatory works well can we ensure that the battery remains in good condition during the idle period, extend its service life and provide reliable power guarantee for the reuse of the forklift.

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