Three key tips for Extending the service life of Forklifts with Lead-acid batteries

Time：2025-07-15 09:35:36

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How to skillfully utilize lead-acid batteries to extend the lifespan of forklifts has become a focus of attention for many enterprises.

In the field of industrial logistics, forklifts, as important handling equipment, their stable performance is directly related to production efficiency. Lead-acid batteries, as the power core of many forklifts, have a profound impact on the service life of forklifts. How to skillfully utilize lead-acid batteries to extend the lifespan of forklifts has become a focus of attention for many enterprises. Next, we will delve into three key techniques for extending the service life of forklifts.
1. Reasonable charging to inject a "source of vitality" into forklifts
(1) Avoid excessive discharge
Question 1: How can one determine if the lead-acid battery of a forklift has been over-discharged?
Answer: Most electric forklift controllers are equipped with under-voltage protection functions. When the battery gauge shows that there is only one bar of battery left, this is often a dangerous signal, indicating that the battery may be approaching the verge of over-discharge. Once over-discharged, lead sulfate in the pores of the battery plates will crystallize into larger particles, forming irreversible sulfation, which greatly increases the internal resistance, deteriorates the subsequent charging recovery ability, and in severe cases, it may even be irreparable. So, when you see the battery gauge indicating low power, you should immediately stop using the forklift and charge the battery as soon as possible.
(2) Charge in a timely manner
After the battery discharges, the sulfation process begins immediately, and the sulfation phenomenon becomes increasingly obvious after 12 hours. A layer of white coarse-grained lead sulfate will form on the plates. It not only severely blocks the pores of the plates, reducing the penetration ability of the electrolyte and resulting in a decrease in battery capacity, but also significantly increases the internal resistance of the storage battery, reducing the output power. Timely charging can eliminate mild sulfation. If charging is not timely, sulfation crystals will continue to accumulate and form large crystals, which are difficult for ordinary chargers to handle. Eventually, this will lead to a decrease in battery capacity and a shortened service life. It is recommended that the forklift be charged as soon as possible after each use to keep the lead-acid battery as fully charged as possible.
(3) Control the charging environment
Question 2: How much impact does the charging environment have on lead-acid batteries?
Answer: The impact of the charging environment on lead-acid batteries cannot be underestimated. The optimal ambient temperature for charging is 25℃. Although most chargers nowadays are equipped with automatic control systems that adapt to the ambient temperature, they are still essentially designed for an ambient temperature of 25℃. In summer, it is important to focus on reducing the temperature of the battery to ensure good heat dissipation. It is strictly forbidden to charge it immediately after direct exposure to the scorching sun. At the same time, keep it away from heat sources. In high-temperature environments, it is necessary to fully understand the operating conditions of the battery and the changes throughout its service life. In addition, when charging, do not place the battery in an overly hot environment. Once the battery is heated, take cooling measures and wait until the temperature returns to normal before charging. Moreover, when the depth of battery discharge is relatively shallow or the ambient temperature is high, the charging time should be appropriately shortened.
2. Scientific maintenance to ensure the smooth operation of forklifts
(1) Regularly check the electrolyte level
During the charging and discharging process of lead-acid batteries, the moisture in the electrolyte gradually decreases due to electrolysis and evaporation, causing the electrolyte level to drop. If not replenished in time, it will accelerate the sulfation rate of the battery plates, thereby shortening the service life of the storage battery. For non-maintenance-free batteries, the electrolyte level should be checked regularly to ensure it is 10-15mm higher than the plates. If the level is found to be insufficient, distilled water should be added. It should be particularly noted that drinking purified water should not be used to replace distilled water, as the various trace elements and ions contained in purified water will accelerate the internal self-discharge of the battery and seriously shorten its service life.
(2) Cleaning and Protection
It is crucial to keep the battery surface clean and dry. Residual electrolyte may cause leakage hazards. On a daily basis, you can wipe the surface of the battery with a damp cloth, but do not use dry cloths, feather dusters, etc., to avoid generating static electricity and causing serious consequences such as battery explosion. At the same time, regularly check whether the battery connection parts are firm to prevent loosening. It is also necessary to check whether the battery casing is cracked or leaking. Once any problem is found, stop using it immediately and contact professional personnel for handling. It is strictly forbidden to disassemble it by yourself.
3. Correct Use to Ensure the Forklift moves Forward steadily
(1) Control the depth of discharge
Question 3: What is the specific mechanism by which the depth of discharge affects the service life of lead-acid batteries in forklifts?
Answer: The depth of discharge is a key factor affecting the service life of lead-acid batteries. Generally speaking, the depth of battery discharge should be controlled to no more than 80% of the battery's rated capacity (which is usually indicated on the forklift gauge). When the depth of discharge is too large, the active substances involved in the reaction on the plates increase, and the structure and performance of the plates will be damaged to a greater extent, accelerating the aging and damage of the plates and thereby shortening the service life of the battery. Therefore, during the operation of forklifts, it is necessary to always pay attention to the battery discharge condition and avoid over-discharge.
(2) Avoid abnormal operations
When a forklift is in operation, it is advisable to avoid performing two or more main actions (such as moving forward and lifting the forks) simultaneously. Such operations can cause a large current discharge of the battery, not only shortening its service life but also causing irreversible damage to the battery. In addition, during use, it is necessary to prevent the battery from being subjected to excessive vibration or impact to avoid affecting the performance of the plates and reducing the battery's service life.
By applying the three key techniques of reasonable charging, scientific maintenance and correct usage, the performance advantages of lead-acid batteries can be fully leveraged, effectively extending the service life of forklifts, reducing operating costs for enterprises and enhancing production efficiency. In the daily use of forklifts, it is essential to attach great importance to the maintenance and management of lead-acid batteries to ensure that forklifts can continuously and efficiently serve production operations.

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