Five common mistakes made when charging lead-acid batteries for forklifts

Time：2025-07-18 09:47:01

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This article will provide a detailed analysis of the five most common mistakes made when charging lead-acid batteries for forklifts, helping enterprises avoid risks and reduce costs.

In the field of industrial logistics, forklifts, as important handling equipment, the performance of their lead-acid batteries directly affects the operational efficiency. However, most operators have operational misunderstandings during the charging process, which not only shorten the battery life but also may cause safety hazards. According to industry data, battery failures caused by improper charging account for over 60%, and the annual equipment maintenance costs for enterprises increase by more than 30%. This article will provide a detailed analysis of the five most common mistakes made when charging lead-acid batteries for forklifts, helping enterprises avoid risks and reduce costs.
Error 1: Overcharging is unregulated
Many operators, for the sake of convenience, connect the charger before leaving work and then leave it unattended. Some even let the battery charge continuously for more than 12 hours. The optimal charging time for lead-acid batteries is 8 to 10 hours (slightly varying depending on capacity). Overcharging for more than 12 hours will accelerate the sulfation of the plates, cause excessive decomposition of water in the electrolyte, and when the internal temperature of the battery rises above 45℃, dangerous situations such as bulging and leakage may also occur.
Error 2: Ignoring temperature and humidity in the charging environment
Charging in the corners of warehouses with high temperatures in summer or outdoors without heating in winter is a common mistake. The ideal charging environment temperature for lead-acid batteries is around 25℃. When the ambient temperature exceeds 35℃, the internal chemical reaction rate of the battery accelerates, which will lead to a charging efficiency drop of more than 30%. When the temperature drops below 5℃, the battery capacity will temporarily decrease by 20% to 30%, and forced charging may cause crystallization of the plates.
In addition, charging in a damp environment (such as near a faucet or in areas with water accumulation on the ground) can easily cause oxidation and short circuits at the battery terminals. In severe cases, it may even lead to sparks or fires. It is recommended that enterprises install temperature and humidity meters in the charging area, ensure good ventilation, avoid direct sunlight, and lay insulating rubber MATS on the ground.
Error 3: Skipping battery checks before charging
Many operators pick up the charger and directly connect it, neglecting the basic inspection steps before charging. Whether the battery's appearance is damaged, whether the electrolyte level meets the standard, and whether the terminals are loose - these details directly affect the safety and effectiveness of charging.
If the electrolyte level is lower than the plates (normally it should be 10-15mm higher than the plates), charging will cause the plates to be exposed to the air and oxidize, shortening their service life. Loose terminals can cause poor contact, generating electric sparks during charging and posing an explosion risk. The correct procedure should be as follows: Before charging, first check if there are any cracks in the battery casing, add distilled water to the standard level, wipe the terminals with a dry cloth and apply vaseline to prevent oxidation.
Error 4: Mixing chargers of different models
When the original charger is damaged, some enterprises will temporarily replace it with a charger of another model. This "making do" approach hides huge risks. The charging voltage and current parameters required for lead-acid batteries of different capacities vary significantly. Charging small-capacity batteries with a high-current charger will cause the active material on the plates to fall off. However, when a low-current charger charges a large-capacity battery, insufficient charging will occur, affecting the range of the forklift.
Error 5: Operating at full capacity immediately after charging
When a battery is just fully charged, the internal chemical reactions have not yet fully stabilized. If a forklift is immediately started for heavy-load handling at this time, it will cause a sudden increase in the battery's discharge rate, and the plates are prone to "passivation". If this continues for a long time, the actual capacity of the battery will decline by 20% to 30% compared to its rated capacity.
The correct approach is: After charging is complete, let it stand for 30 minutes to allow the internal temperature of the battery to drop to the ambient temperature. At the same time, check the density of the electrolyte (the standard value is about 1.28g/cm³). Only after confirming that there are no abnormalities can it be put into use. Enterprises with the necessary conditions can record battery capacity test data once a week to promptly identify the trend of performance degradation.
Frequently Asked Questions
Question: Does the forklift battery need to be fully charged every day?
Answer: Yes. Lead-acid batteries have a "memory effect". If they are charged to 80% for a long time and then stopped, they will gradually lose 20% of their capacity. It is recommended to charge the battery in time after each day's work to keep it fully charged, but the charging time should be strictly controlled to no more than 10 hours.
Question: If white powder appears on the battery surface, does it need to be replaced?
Answer: The white powder is lead sulfate produced by the oxidation of the terminal posts, which is a normal phenomenon and does not require immediate replacement. You can rinse it with hot water, dry it and apply Vaseline to solve the problem. However, if the powder is accompanied by leakage or there is obvious corrosion on the plates, it is necessary to contact a professional to test the health status of the battery.
Summary
The service life of lead-acid batteries for forklifts is usually 3 to 5 years. However, in most enterprises, due to improper charging operations, the batteries are scrapped 1 to 2 years ahead of schedule. By avoiding the above five mistakes and combining with balanced charging once a month (charging the battery to 100% and then continuing to charge for 2 hours), the battery life can be effectively extended by more than 30%. It is suggested that enterprises formulate a "Battery Management Manual", provide specialized training for operators, incorporate charging norms into the daily equipment inspection list, reduce operating costs from details, and ensure operation safety.

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