Forklift lead-acid battery maintenance tips to help you save a lot of expenses

Time：2025-03-28 17:43:59

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Careful maintenance of lead-acid batteries can not only extend their service life, reduce the frequency of replacement, but also ensure the stable operation of forklifts and avoid production stagnation caused by battery failure.

In logistics warehousing, industrial manufacturing and other fields, forklift as an important material handling equipment, its power source - lead-acid battery maintenance status, has a profound impact on enterprise operating costs. Careful maintenance of lead-acid batteries can not only extend their service life, reduce the frequency of replacement, but also ensure the stable operation of forklifts and avoid production stagnation caused by battery failure. The following details for you to uncover the forklift lead-acid battery maintenance secrets.

1. Daily appearance inspection

Before and after daily operation, the appearance inspection of lead-acid batteries of forklift trucks is a basic and critical step. First, check whether the battery case is damaged, deformed or cracked. Even a slight crack may lead to electrolyte leakage, which will not only corrode peripheral equipment, but also seriously affect battery performance. If the shell is faulty, replace the battery in time to avoid greater losses.

Check the battery pole and connection line can not be ignored. Pole should have no signs of corrosion, if there is white or green corrosion, need to clean up immediately. Gently wipe the pole with baking soda (dissolve an appropriate amount of baking soda in water) to neutralize the corrosion, and then dry with a clean cloth. At the same time, ensure that the connection cable is firmly connected. Loose connection cables will increase the resistance, resulting in poor current transmission, affecting the power output of the forklift truck, and may cause overheating or even fire and other safety hazards.

2.Electrolyte management

The electrolyte of a lead-acid battery is composed of sulfuric acid and water, and its level and density are crucial to the battery performance. Check the electrolyte level regularly. Under normal circumstances, the liquid level should be between the upper and lower limits marked on the battery case. If the liquid level is too low, the plate will be partially exposed to the air, causing the plate to vulcanize and shorten the battery life. If the liquid level is too low, it is necessary to add distilled water or special lead-acid battery supplement liquid, do not add tap water, tap water impurities will affect the internal chemical reaction of the battery.

The density of the electrolyte also needs to be measured regularly, generally using a density meter for detection. The electrolyte density has a suitable range under different seasons and battery usage conditions. For example, in summer, the optimum density is about 1.24-1.26 g/cm³; In winter, it is slightly higher, about 1.26-1.28 g/cm³. The density is too high or too low, which means that the chemical reaction inside the battery may be abnormal, and it needs to be adjusted in time. If the density is too high, an appropriate amount of distilled water can be added to dilute; If it is too low, the battery may be overdischarged or faulty, need to further investigate the cause and charge or repair.

3.Charging skills control

The correct charging method can effectively extend the service life of lead-acid battery of forklift truck. First of all, use a charger that matches the battery specifications, and avoid using poor quality or mismatched chargers to prevent overcharging or undercharging. Overcharge will heat the battery, accelerate the evaporation of electrolyte water, and even cause thermal runaway; Insufficient charging will cause the plate to vulcanize and reduce the battery capacity.

During the charging process, the principle of "shallow charging and shallow discharge" should be followed. Try to avoid excessive battery discharge, when the power remaining 20%-30%, it should be charged in time. Excessive discharge will cause a large number of lead sulfate crystals on the plate to be generated and difficult to reduce, and over time, the battery capacity will be greatly reduced. At the same time, do not frequently deep charge the battery, each charge to about 80%-90%, which can reduce the loss of the battery plate.

In addition, the charging environment temperature will also affect the charging effect and battery life. The appropriate charging temperature for lead-acid batteries is about 25 ° C, and too high or too low a temperature will reduce the charging efficiency and even damage the battery. When charging in high temperature environment, ventilation and heat dissipation measures can be taken; In low temperature environment, the charger with temperature compensation function can be used to automatically adjust the charging voltage and current to adapt to the low temperature environment.

4. Regular deep maintenance

In addition to daily maintenance, forklift lead-acid batteries need to be regularly maintained in depth. Every once in a while, the battery should be tested for capacity. Through the professional battery capacity tester, simulate the discharge process under the actual working state of the battery, accurately measure the battery capacity. If the battery capacity is found to be significantly reduced, a deep charge and discharge can be attempted, that is, the battery is fully discharged first, and then charged for a long time with small current, which helps to activate the active substance on the plate and restore part of the battery capacity.

Regular inspection of the internal resistance of the battery is also an important part of deep maintenance. The increase of internal resistance is one of the important signs of battery aging, which can be measured by using an internal resistance tester. If the internal resistance exceeds the normal range, it indicates that there may be plate vulcanization or electrolyte drying inside the battery. Repair or replace the battery in time.

By following these tips for forklift lead-acid battery maintenance, companies can significantly extend battery life, reduce battery replacement costs, reduce the risk of downtime caused by battery failure, and in the long run, save a lot of money for companies and improve overall operational efficiency.

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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