Forklift lead-acid battery emergency guide

Time：2025-03-31 09:53:36

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The following first aid guide will help you respond quickly and minimize damage in an emergency.

In logistics warehousing, factory production and other scenarios that rely on forklift operations, once the forklift lead-acid battery fails suddenly, it is very likely to disrupt the entire rhythm of work, and even cause safety problems. The following first aid guide will help you respond quickly and minimize damage in an emergency.

## The battery expands and deforms

### Fault performance

During the use of forklift trucks, if the battery shell is found to bulge and deform, and the temperature is abnormally high when touched, this is a typical sign of battery expansion. This fault is usually caused by overcharging, charging equipment failure to make the charging voltage is too high, or long-term overcharging, so that the battery internal too much gas, burst the shell; Poor heat dissipation is also to blame, the forklift operating environment temperature is high, the battery heat dissipation space is blocked by debris, heat accumulation, accelerate the chemical reaction inside the battery out of control, causing expansion.

### First aid measures

Stop the forklift immediately and disconnect the battery from the forklift to avoid short circuit. Do not attempt to continue charging, move the forklift to an open area with good ventilation and away from flammable materials, evacuate surrounding people, and prevent a possible explosion of the battery. At the same time, contact professional maintenance personnel, who will carry professional tools to detect battery voltage, internal resistance and other parameters to determine whether the battery can be repaired, if it cannot be repaired, it is necessary to replace the new battery in time.

## Electrolyte leakage

### Fault performance

There is an unknown liquid on the ground where the forklift is parked, and the battery shell has white crystals or liquid flowing traces, and a pungent and sour taste can be smelled close up, which indicates that the electrolyte has leaked. Severe vibration and battery collision during forklift handling, causing the shell to crack; Or the battery life is long, the shell aging, corrosion, may lead to electrolyte leakage.

### First aid measures

Wear protective equipment, such as acid-resistant gloves, protective glasses, and protective clothing, to prevent the electrolyte from burning the skin and eyes. Flush the leakage area with plenty of water to dilute the acidity of the electrolyte and reduce the corrosion. For the leakage of electrolyte on the ground, can be sprinkled with lime powder, baking soda and other alkaline substances to neutralize, and then covered with sand to clean up. Carefully check the battery shell damage, if the damage is small, try to repair with special sealant; If the damage is serious, replace the battery. During the replacement process, properly collect the leaking electrolyte and dispose of it as hazardous waste to avoid environmental pollution.

## Battery cannot be charged

### Fault performance

When the forklift truck is connected to the charging device, the charging indicator is not on, the battery power does not rise significantly, and the charging device even reports an error message. This is mostly because the charging line is broken, the plug is loose, the wire is damaged, and the current cannot be transmitted; The internal plate of the battery is vulcanized, the battery suffers from long-term power loss, the electrolyte dries up, and white lead sulfate crystals are formed on the surface of the plate, hindering the electrochemical reaction. Or the battery is aging, the internal structure is damaged, and the capacity is greatly reduced.

### First aid measures

First check the charging line, check whether the plug is plugged in, whether the wire is damaged or broken, if there is a problem, repair or replace the line in time. Then clean the battery pole to remove surface oxides to ensure a good connection. Try to activate and charge the battery with a small current. If it still cannot be charged, use a professional battery detector to detect the internal resistance and voltage distribution of the battery to determine whether the battery is scrapped. If the battery has reached its service life, replace it with a new battery as soon as possible, and conduct a charge and discharge test after replacement to ensure that the new battery works properly.

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