Guide to the Use and Maintenance of Lead-Acid Batteries for Forklifts

Time：2025-07-26 11:50:23

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Therefore, mastering the correct usage and maintenance methods of lead-acid batteries for forklifts is the key to ensuring the efficient and safe operation of forklifts.

In the logistics and transportation process of industrial production, forklifts play a crucial role. As the power source of forklifts, the performance of forklift lead-acid batteries directly affects the working efficiency, endurance and service life of forklifts. If the use and maintenance of storage batteries are improper, it will not only increase the equipment maintenance costs of enterprises, but also may affect the production progress due to sudden malfunctions, and even cause safety accidents. Therefore, mastering the correct usage and maintenance methods of lead-acid batteries for forklifts is the key to ensuring the efficient and safe operation of forklifts.
1. Usage Specifications for Lead-Acid Batteries in Forklifts
(1) Correct operation in the charging process
The charging process of forklift lead-acid batteries is a key link affecting their lifespan and must strictly follow the following norms:
First of all, the charging environment should be well-ventilated. Because the battery generates a mixture of hydrogen and oxygen during charging, poor ventilation may cause the gas to accumulate, and it is very likely to explode when exposed to open flames. At the same time, charging areas should be kept away from fire sources and heat sources, and smoking is strictly prohibited.
Secondly, use the original charger that matches the model of the battery. Batteries of different models have different parameters such as voltage and capacity. Mixing chargers can lead to undercharging or overcharging, seriously affecting the battery's lifespan and even causing damage to it.
In addition, the charging time should be reasonably controlled. When the battery power is consumed to 70%-80% of its rated capacity, it should be charged in time to avoid over-discharge. Under normal circumstances, charging should be stopped immediately after a full charge. Overcharging will cause a large amount of water in the electrolyte to evaporate, leading to sulfation of the plates and a reduction in the battery's capacity.
(2) Precautions during the discharge process
During the operation of forklifts, there are also many points to note when discharging the battery. To avoid prolonged high-current discharge, such as frequent starts and sudden acceleration of forklifts, the instantaneous discharge current of the battery will be too large, causing the active material on the plates to fall off and shortening the battery's lifespan.
At the same time, deep discharge of the battery should be avoided. When the forklift's instrument panel shows that the battery is low, operation should be stopped as soon as possible and charging should be carried out. Do not force it to continue using, otherwise it will cause irreversible damage to the internal structure of the battery.
(3) Control of the operating environment
Forklift lead-acid batteries are relatively sensitive to temperature, and the suitable working temperature is around 25℃. When used in a high-temperature environment, it will accelerate the chemical reactions inside the battery, causing the electrolyte to evaporate too quickly and intensifying the corrosion of the plates. In low-temperature environments, the capacity of the battery will significantly decrease and its discharge capacity will weaken. At this time, the operation time should be shortened as much as possible, and the battery should be charged in a timely manner after the operation is completed.
In addition, it is necessary to avoid subjecting the battery to severe vibration and collision. When forklifts are traveling on rough roads or transporting goods, they should slow down to prevent the internal plates of the battery from falling off and the separators from being damaged, which may affect the performance of the battery.
2. Key Points for Maintaining Lead-Acid Batteries in Forklifts
(1) Daily inspection work
Before using the forklift every day, a comprehensive inspection of the battery should be carried out. First, check if the battery casing is damaged or deformed. If any damage is found, stop using it immediately to prevent electrolyte leakage. Secondly, check if the terminals are loose or oxidized. If there is any oxidation, rinse them with hot water, dry them, and then apply Vaseline to prevent further oxidation.
It is also necessary to check the liquid level of the electrolyte. The electrolyte level should be 10 to 15mm higher than the plates. If the liquid level is lower than the lowest mark, distilled water should be added in time. Do not add tap water or electrolyte. Because tap water contains minerals, it can contaminate the electrolyte and affect the performance of the battery. However, adding electrolyte will cause the concentration of the electrolyte to be too high, which will aggravate the corrosion of the plates.
(2) Regular cleaning and maintenance
Regular cleaning of the battery can effectively extend its service life. When cleaning, first wipe the dust and dirt on the surface of the battery with a dry cloth, then use baking soda water to wipe the terminals and the casing to neutralize any possible acidic substances, and finally rinse thoroughly with clean water and dry.
At the same time, it is necessary to keep the vent holes on the battery cover unobstructed to prevent the vent holes from being blocked, which may prevent the gas from being discharged and cause the battery to bulge or explode.
(3) Maintenance for long-term storage
If the forklift needs to be stored for a long time, special maintenance should be carried out on the battery. First, fully charge the battery, then disconnect the battery from the forklift to prevent it from discharging by itself. During storage, the battery power should be checked once a month. If the power is insufficient, it should be recharged in time.
The storage environment should be dry and well-ventilated, avoiding direct sunlight and high-temperature conditions. At the same time, it is necessary to prevent the battery from being squeezed or collided.
3. Frequently Asked Questions and Answers
(1) What should be done if the temperature of the lead-acid battery of a forklift is too high during charging?
When the battery temperature is too high during charging, it may be caused by excessive charging current, too long charging time or internal short circuit of the battery, etc. At this point, charging should be stopped immediately and the charger should be checked to see if it matches the battery. If the charger is functioning properly, there might be an internal fault with the battery. Professional maintenance personnel should be contacted promptly for inspection and repair. Do not continue charging to avoid danger.
(2) How to deal with the leakage of battery electrolyte?
If leakage of the electrolyte in the battery is detected, the forklift should be stopped immediately. Wear protective gloves and glasses, use a dry cloth to absorb the leaked electrolyte, then rinse the leakage area with baking soda water to neutralize the acidic substances. Finally, send the battery to a professional maintenance institution for inspection and repair. During the handling process, it is necessary to avoid the electrolyte coming into contact with the skin and eyes. If contact occurs accidentally, rinse immediately with plenty of water and seek medical attention promptly.
In conclusion, the use and maintenance of lead-acid batteries for forklifts is a meticulous and significant task that requires the high attention of operators and managers. Only by strictly following the correct usage norms and doing a good job in daily maintenance and upkeep can the service life of the battery be effectively prolonged, the operating costs of the enterprise be reduced, and the safe and efficient operation of forklifts be guaranteed.

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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