Quick location of Common Faults of forklift lead-acid batteries

Time：2025-07-22 10:38:10

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Once the battery malfunctions, it will not only affect the normal operation of the forklift but also may lead to production interruption and cause economic losses.

In the operation of forklifts, lead-acid batteries play a crucial role in providing continuous power for the forklifts. Once the battery malfunctions, it will not only affect the normal operation of the forklift but also may lead to production interruption and cause economic losses. Therefore, it is of vital importance to quickly locate and resolve common faults of storage batteries.
Troubleshooting for failure to charge
Failure to charge is one of the common faults of lead-acid batteries in forklifts. When encountering such a situation, you can follow the steps below to troubleshoot.
First, check if the charger is working properly. Check if the indicator light of the charger is on. If the indicator light is not on, it may be that the power plug of the charger is not inserted tightly, the power cord is broken, or the internal components of the charger are damaged. You can try to replace it with a known normal charger for testing. If it can charge normally after replacement, it indicates that there is a problem with the original charger.
Secondly, check the connection lines between the battery and the charger. Loose connection lines, oxidized plugs or broken lines can all lead to an unobstructed charging circuit, preventing normal charging. Carefully observe whether there is any oxidation at the plug. If so, you can sand it clean with sandpaper and then reconnect it. At the same time, check if there is any damage to the circuit. If there is any damage, replace the circuit in time.
In addition, problems with the battery itself may also cause it to fail to charge. If the internal plates of a storage battery are severely sulfated, a layer of lead sulfate crystals that are difficult to conduct electricity will form on the surface of the plates, hindering the charging process. At this point, the terminal voltage of the battery may be relatively high, but the charging current is very small. In this case, desulfurization treatment of the battery is required. If the treatment is ineffective, the battery needs to be replaced.
Analysis of the reasons for capacity decline
A decrease in battery capacity will directly lead to a reduction in the forklift's endurance, affecting work efficiency. The main reasons for the decline in capacity are as follows.
Temperature has a significant impact on the capacity of storage batteries. In a low-temperature environment, the rate of chemical reactions inside the battery slows down, and the utilization rate of active substances decreases, thereby leading to a reduction in capacity. In this case, the battery can be moved to an environment with a suitable temperature (generally around 25℃), and then its capacity can be tested to see if it has recovered. If the capacity increases after the temperature rises, it indicates that the capacity decrease is caused by the temperature factor.
If a storage battery is in a state of undercharging for a long time, the lead sulfate on the plates cannot be fully converted into active substances, gradually forming sulfation, which in turn leads to a decrease in capacity. At this point, it is necessary to check whether the charging system is reasonable to ensure that the battery is fully charged each time. Equalization charging can be adopted to fully charge the battery once to restore part of its capacity.
In addition, faults such as the detachment of internal plates and short circuits in the battery can also cause a decrease in capacity. If this is suspected, it can be determined by measuring the voltage of each individual battery in the storage battery. Under normal circumstances, the voltages of each individual battery should be basically the same. If the voltage of a certain individual battery is significantly low, it may indicate a plate detachment or short circuit fault, and the battery needs to be replaced.
Fault diagnosis of bulging and leakage
Battery swelling and leakage are rather serious malfunctions. If not dealt with promptly, they may lead to safety accidents.
Battery bulging is mainly caused by overcharging. Overcharging will cause a large amount of gas to be produced inside the battery. If the gas cannot be discharged in time, it will cause the battery casing to bulge. At this point, charging should be stopped immediately. Check whether the charging parameters of the charger meet the requirements of the battery. If the parameters of the charger are abnormal, the charger needs to be replaced. At the same time, the bulging battery can no longer be used normally and should be replaced in time.
The leakage fault may be caused by the rupture of the battery casing or the aging of the sealant. Check if there are any cracks in the battery casing. If there are cracks, they are usually caused by external force impact or aging due to long-term use. In such cases, the battery needs to be replaced. In addition, check whether the sealant of the battery is loose or aged. If the sealant problem causes leakage, you can reapply the sealant for repair. However, if the leakage is severe, the battery still needs to be replaced.
Frequently Asked Questions and Answers
Question: What could be the reasons for a sudden power outage of a lead-acid battery in a forklift during use?
Answer: If the lead-acid battery of a forklift suddenly loses power, there may be the following reasons. One is that the internal connection lines of the battery are broken, resulting in the inability to output current. You can check whether the internal connection strips of the battery are intact. The second reason is that the main switch of the battery has poor contact or is damaged, causing the circuit to be interrupted. You can check the connection of the main switch and replace it if necessary. Thirdly, if a single battery of the storage battery experiences a short circuit fault, causing the battery to fail to supply power normally, it can be determined by measuring the voltage of each individual battery, and the faulty battery should be replaced.
Question: How can one determine whether a battery needs to be replaced by its appearance?
Answer: Whether a battery needs to be replaced can be judged from the following aspects based on its appearance. First, observe whether there is any severe bulging or cracking on the battery casing. If so, it indicates that the battery is severely damaged and must be replaced. Secondly, check if the plates are exposed. If they are exposed, it will affect the performance and safety of the battery and they need to be replaced. In addition, if the battery leaks severely and the problem still cannot be solved after repair, the battery should also be replaced.
Daily maintenance and fault prevention
To reduce the faults of lead-acid batteries in forklifts, daily maintenance is indispensable. Regularly check the liquid level of the battery to ensure that the electrolyte level is within the specified range. If the liquid level is too low, distilled water should be added. Keep the surface of the battery clean and dry to avoid short circuits caused by dust and impurities. Charge the battery in accordance with its charging requirements to avoid overcharging or undercharging. In low-temperature environments such as winter, it is necessary to do a good job in insulating the battery to improve its working efficiency.
Through the above analysis and troubleshooting methods for common faults of lead-acid batteries in forklifts, it is hoped that it can help relevant personnel quickly locate the faults, take timely measures to solve the problems, and ensure the normal operation of forklifts. At the same time, doing a good job in daily maintenance can effectively extend the service life of the battery and reduce the occurrence rate of faults.

Statement: The articles on this site are written by the GSGT team or reprinted from other media or compiled by AI.No reproduction without permission.For copyright or other issues, please contact:gsgtpower@163.com.

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