The correct steps for dealing with acid leakage in forklift lead-acid batteries

Time：2025-07-18 10:04:10

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Mastering the correct acid leakage treatment steps is the key to ensuring equipment safety and personnel health.

In the daily use of forklifts, acid leakage from lead-acid batteries is a problem that cannot be ignored. The leaked electrolyte contains sulfuric acid and is highly corrosive. It not only damages the components of the forklift and pollutes the environment, but also may cause harm to the operators. Mastering the correct acid leakage treatment steps is the key to ensuring equipment safety and personnel health.
Ⅰ. Hazards and Common Causes of Acid Leakage
(1) Hazards of acid leakage
The electrolyte leaked from lead-acid batteries is mainly composed of sulfuric acid, and its concentration is usually between 30% and 40%. This acidic liquid, when in contact with metals, can cause corrosion, leading to rust and damage to components such as the battery compartment and terminal posts of forklifts. It may drip onto the ground or goods, causing ground cracking and goods contamination. If it comes into direct contact with the skin, it may cause burns and redness. If it splashes into the eyes, it may lead to serious eye damage. In addition, acid leakage is accompanied by the loss of electrolyte, leading to a decrease in battery capacity, shortened battery life, and even battery scrapping.
(2) Common causes of acid leakage
Acid leakage does not occur suddenly; it is often related to improper long-term use or lack of maintenance.
Shell damage: The jolts and collisions during forklift operation, or the severe vibrations when the battery is placed, may cause cracks in the battery shell (mostly made of plastic).
Seal failure: The aging of the sealant between the battery cover plate and the casing, as well as the damage of the terminal post sealing ring, will cause the electrolyte to seep out from the gap.
Overcharging leads to expansion: Prolonged overcharging will cause a large amount of gas to be generated inside the battery. The shell will bulge and deform due to excessive pressure, and eventually rupture and leak acid.
Plate detachment: When the battery has been in use for too long or undergoes frequent deep discharges, the active material on the plates may fall off and accumulate, which may Pierce the separator or the casing, causing acid leakage.
Ⅱ. Correct Steps for acid leakage Treatment
The treatment of acid leakage should follow the principle of "safety first and scientific handling". The specific steps are as follows:
(1) Emergency protection and isolation of the scene
Upon discovering acid leakage, immediately stop the forklift operation, park the vehicle in a well-ventilated area away from fire sources and crowds, set up warning signs, and prohibit irrelevant personnel from approaching. Operators must wear protective equipment: acid-resistant gloves (to avoid direct contact with acid), goggles (to prevent acid from splashing into the eyes), rubber aprons (to protect clothing and skin). If there is a large amount of acid leakage, gas masks should also be worn (to prevent inhalation of volatile acidic gases).
(2) Clean up the leaked electrolyte
Gently wipe the leaked acid solution with a dry cloth or absorbent cotton (be careful not to wipe too hard to avoid acid splashing). Put the waste after wiping into a special acid-resistant container and do not discard it at will. For residual acid on the ground or battery surface, it should be neutralized with a weakly alkaline solution: Mix baking soda (sodium bicarbonate) with water in a ratio of 1:10, stir evenly, then spray the solution onto the contaminated area with a spray bottle. Let it stand for 5 to 10 minutes (slight bubbles may form during this period, which is a normal neutralization reaction), then rinse thoroughly with clean water, and finally dry with a dry cloth.
Note: Do not use strong alkali (such as sodium hydroxide) for neutralization to avoid overly intense reactions that generate high temperatures and cause secondary injuries.
(3) Check the location and cause of acid leakage
After neutralization and cleaning, carefully inspect the battery's acid leakage points: If there are obvious cracks in the shell, mark the damaged location; If there is acid leakage at the terminal post, check whether the sealing ring is aged or broken. If acid leakage occurs at the edge of the cover plate, check whether the sealant has fallen off. At the same time, record the usage conditions before the acid leakage occurs (such as whether the charging has just been completed, whether there has been any collision recently, etc.) to facilitate the determination of the cause of the acid leakage.
(4) Temporary handling and follow-up measures
If the acid leakage is small and the leakage point is small (such as the sealing ring of the terminal post is aged), you can first replace the sealing ring of the same model, add an appropriate amount of distilled water (do not add tap water or electrolyte to avoid abnormal concentration) to replenish the liquid level, and maintain the use temporarily, but the inspection cycle needs to be shortened and professional maintenance should be arranged as soon as possible.
If the shell is cracked or bulges and leaks acid, it must not be used any longer. Professional technicians should be contacted to replace the battery. Do not disassemble or repair it by yourself (which may cause the acid leakage to worsen).
All tools (rags, containers, etc.) that have come into contact with acid solution should be soaked in baking soda solution for 30 minutes before cleaning to prevent residual acid from corroding other items.
Ⅲ. Frequently Asked Questions
(1) Can a battery that leaks acid still be used?
Whether it can continue to be used depends on the degree of acid leakage: If there is only slight acid leakage and the leakage point can be repaired (such as the sealing ring problem), it can be used for a short period after professional treatment, but close observation is required. If the shell is cracked, bulged or leaks a large amount of acid, it must be immediately shut down and replaced. Continuing to use damaged batteries will cause continuous leakage of acid, which not only damages the equipment but may also lead to safety accidents such as battery short circuits and fires.
(2) What should be done if the skin comes into contact with acid when dealing with acid leakage?
Once the skin comes into contact with the acid solution, immediately rinse the affected area with plenty of running water (for at least 15 minutes), and remove contaminated clothing during the rinsing process. If the skin shows redness, swelling or pain, apply weakly alkaline ointment (such as zinc oxide ointment) promptly and seek medical attention for examination. If acid splashes into the eyes, do not rub them. Immediately lift the eyelids and rinse with clean water for 10 to 15 minutes. Then, seek medical attention at the ophthalmology department of a hospital as soon as possible. Do not delay treatment.
(3) How to prevent acid leakage in forklift lead-acid batteries?
To prevent acid leakage, daily maintenance should be done well
Regularly inspect the appearance of the battery. Check the shell for cracks or bulges every week, and whether the terminals are loose or corroded. Deal with any problems found in a timely manner.
Standardize the charging operation, use the original charger, avoid overcharging (cut off the power in time after full charging), and control the charging environment temperature at around 25℃ (high temperature will accelerate the aging of sealing parts).
Avoid violent collisions. Slow down when moving the forklift and keep it away from hard objects when parking.
Use the battery reasonably according to its capacity, avoid frequent deep discharge (charge it in time when the battery level drops below 20%), and extend the battery's service life.
Ⅳ. Summary
Although acid leakage from lead-acid batteries in forklifts is a common problem, improper handling can pose safety hazards. Mastering the steps of "protection - neutralization - inspection - handling" can not only reduce equipment damage but also ensure the safety of operators. At the same time, regular battery maintenance can reduce the risk of acid leakage from the source and improve the operational efficiency of forklifts. Remember: When it comes to acid leakage, taking it lightly will only cost you more. Scientific handling is the key.

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