Emergency start-up methods for forklift lead-acid batteries in case of power failure

Time：2025-07-28 11:17:19

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This article will provide a detailed introduction to the common causes of power failure of lead-acid batteries in forklifts, emergency start-up methods, and related precautions, to help everyone quickly deal with such problems.

In the daily operation of forklifts, a power outage of lead-acid batteries is a common and unexpected situation. If it is not resolved in time, it will seriously affect the work progress. This article will provide a detailed introduction to the common causes of power failure of lead-acid batteries in forklifts, emergency start-up methods, and related precautions, to help everyone quickly deal with such problems.
Common causes of power failure of lead-acid batteries in forklifts
The power failure of lead-acid batteries in forklifts is not accidental and is usually caused by multiple factors. Battery aging is one of the common causes. Lead-acid batteries have a certain service life. As the usage time increases, the internal plates of the battery will gradually sulfate and corrode, resulting in a decrease in capacity. When the capacity cannot meet the starting requirements of the forklift, a power outage will occur.
Circuit faults may also cause power outages. During the long-term use of forklifts, the circuits may become loose, short-circuited or open due to vibration, friction and other reasons. For instance, loose battery terminals can lead to poor contact and prevent normal current transmission. If the insulation layer of the line is damaged, it may cause a short circuit, resulting in an instant power outage of the battery.
In addition, over-discharging can also cause the battery to lose power. If the forklift operator continues to use the forklift when the battery power is low, it will cause excessive discharge of the battery. In severe cases, it may damage the internal structure of the battery and prevent it from supplying power normally.
Emergency activation method
Temporary start method (bridging start)
Jumper start is a commonly used temporary emergency method, which is suitable for situations where there are other normally working forklifts or appropriate power sources on site. The specific steps are as follows:
Prepare the jumper cable (ground wire) and ensure that the rated current of the cable can meet the starting requirements of the forklift. Generally, it is recommended to choose a cable with a larger cross-sectional area to reduce resistance and energy loss.
Park the two forklifts (or other power sources and faulty forklifts) steadily and keep a certain distance from each other to avoid contact between the two vehicles. Turn off the engines and electrical equipment of all vehicles to prevent short circuits.
Confirm the positive and negative poles of the jumper cable. The red cable is the positive pole and the black cable is the negative pole. First, connect one end of the red cable to the positive terminal of the faulty forklift battery, and the other end to the positive terminal of the normal vehicle battery.
Next, connect one end of the black cable to the negative terminal of the normal vehicle battery, and the other end to the metal body of the faulty forklift (away from the battery to avoid sparks that could cause danger), rather than directly to the negative terminal of the faulty battery.
Start the engine of a normal vehicle and let it idle for 2 to 3 minutes to replenish some power to the faulty battery.
Try to start the faulty forklift. If it starts successfully, remove the jumper cables in the reverse order of connection. First, remove the black cable, and then the red cable.
The method for starting the battery after replacement
If the faulty battery cannot be restored to power supply through jumper startup, or if the battery is severely damaged, a new battery needs to be replaced. The steps are as follows:
Prepare new lead-acid batteries that match the forklift model, as well as tools such as wrenches and screwdrivers.
Turn off the power switch of the forklift to ensure it is in a power-off state and avoid electric shock or short circuit accidents during the replacement process.
When disassembling the connection wires of an old battery, first remove the negative terminal connection wire, then the positive terminal connection wire. Be careful not to let the tool touch both the positive and negative terminals at the same time to avoid sparks.
Remove the old battery, clean the dust and debris at the battery installation location, and check whether the battery bracket is intact. If any damage is found, repair it in time.
Place the new battery in the installation position and connect the battery connection wires in the order of positive terminal first and then negative terminal. Make sure the connection is firm and there is no loosening on the terminals.
Check the battery's fixation to ensure it is securely installed and will not shake during the forklift's operation.
Turn on the power switch and test whether the forklift can start and operate normally.
Q&A session
Question: What safety precautions should be taken during cross-connection startup?
Answer: When initiating a cross-connection, there are multiple safety precautions to be taken. First of all, it is essential to ensure that the positive and negative poles of the jumper cable are connected correctly and not in reverse; otherwise, it may cause a short circuit in the battery, damage electrical equipment, or even lead to a fire. Secondly, when connecting and removing cables, be sure to avoid the tools coming into contact with the positive and negative terminals of the battery and other metal parts to prevent sparks. In addition, during the startup process, the operator should stay away from the battery to prevent injury caused by battery leakage or explosion. At the same time, the engine of a normal vehicle should be kept idling and not running at high speed to avoid excessive load on the battery and electrical system.
Question: Is there any damage to the forklift battery after emergency activation?
Answer: If the emergency start itself is operated correctly, it generally will not cause significant damage to the forklift battery. However, if not operated properly, it may have certain impacts. For instance, when starting with a jumper, if the positive and negative terminals are reversed, it can cause a short circuit in the battery, generating a large current instantly, damaging the internal plates and separators of the battery. In severe cases, it may even lead to the battery being scrapped. In addition, frequently using the jumper start method will keep the faulty battery in a state of low power for a long time, accelerating the aging and damage of the battery. If it is started with a new battery, as long as the new battery model matches and is installed correctly, it usually will not cause damage to the forklift and the battery. Therefore, when performing emergency start-up, it is essential to strictly follow the correct operation procedures to avoid battery damage due to operational errors.
Summary
Power failure of lead-acid batteries in forklifts can cause many inconveniences to work. It is crucial to understand the common causes of power failure and emergency start-up methods. In actual operation, whether it is cross-connection start-up or battery replacement start-up, safety operation procedures must be strictly followed to ensure the safety of personnel and equipment. At the same time, it is necessary to do a good job in the maintenance and care of the battery on a daily basis. Regularly check the battery's power level, connection wires and appearance condition, promptly identify and solve problems, reduce the occurrence of power outages, and improve the working efficiency of the forklift.

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