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In modern logistics and industrial production, forklifts play a crucial role. As one of the main power sources for forklifts, the correct selection of lead-acid batteries has a profound impact on the performance, efficiency and service life of forklifts. Due to the differences in design, application and technical parameters, forklifts of different brands are suitable for different types of lead-acid batteries. Next, we will delve into the relevant content of common forklift brands and compatible lead-acid battery models, providing you with a comprehensive and practical guide in forklift battery selection.

1. Types and Characteristics of Lead-Acid Batteries for Forklifts

(1) Flooded lead-acid battery

Flooded lead-acid batteries, often also known as open-type lead-acid batteries, are the most traditional and widely used type of forklift battery. The electrolyte inside is a flowing dilute sulfuric acid solution, and the plates are completely immersed in it. The outstanding advantage of this type of battery lies in its relatively low cost and excellent high-current discharge performance, which can meet the demand for instantaneous high power when forklifts start, accelerate and handle heavy objects. In addition, by regularly adding distilled water to replenish the water loss caused by the electrolysis of water during the charging process, its normal operation can be maintained. Under reasonable maintenance, its cycle service life is relatively long, generally reaching 1,000 to 1,500 charge and discharge cycles. However, it also has some obvious drawbacks, such as the need for regular maintenance and a relatively cumbersome maintenance process; When charging, flammable and explosive gases such as hydrogen are produced, and the ventilation conditions of the charging environment are required to be relatively high. Moreover, due to the presence of flowing electrolyte inside, there is a risk of electrolyte leakage when the battery is tilted or subjected to severe vibration, which may cause damage to the equipment and the environment.

(2) Maintenance-free lead-acid batteries

Maintenance-free lead-acid batteries mainly include valve-regulated sealed lead-acid batteries (VRLA), which are further divided into two types: gel batteries and AGM (adsorption glass fiber cotton) batteries. The electrolyte of colloid batteries adopts colloidal substances, solidifying the sulfuric acid electrolyte in silica gel, which avoids the flow of the electrolyte and effectively prevents leakage problems. AGM batteries utilize adsorption-type glass fiber cotton separators to adsorb the electrolyte, achieving the same sealed and maintenance-free feature. The greatest advantage of maintenance-free lead-acid batteries lies in the fact that they require almost no daily maintenance, significantly reducing the cost and time of manual maintenance. Meanwhile, due to its sealed design, the amount of gas escaping is extremely small, making it safer to use. It has relatively lower requirements for the charging environment and can operate in relatively harsh conditions. They have a low self-discharge rate and can maintain their power for a long time. However, the manufacturing cost of maintenance-free lead-acid batteries is relatively high, which leads to their market price being higher than that of flooded lead-acid batteries. Moreover, in terms of battery capacity and high-current discharge capability, it may be slightly inferior to high-quality flooded lead-acid batteries. The cycle life is generally around 800 to 1,200 charge and discharge cycles.

2. Common lead-acid battery models for forklifts of various brands

(1) Heli Forklift

As a well-known domestic brand, Heli forklifts offer a wide range of product models and are widely used in various logistics, warehousing and industrial production scenarios.

1. ** 1-2 ton electric forklifts ** : Such as CPD10, CPD15 and other models, are usually compatible with 48V lead-acid batteries. For some working conditions with high intensity and frequent use, 48V 600AH or 48V 700AH batteries can also be selected. They have a larger capacity, which can effectively extend the continuous working time of forklifts, reduce the frequency of charging, and improve work efficiency.

2. ** 2-3 ton electric forklifts ** : Models like CPD20, CPD25, CPD30, etc., partially compatible with 48V high-capacity batteries, such as 48V 600AH, 48V 700AH, etc. Some larger-tonnage models, such as the CPD30, are also compatible with 80V batteries. Common ones include 80V 480AH and 80V 500AH. These high-voltage and large-capacity batteries can provide forklifts with stronger power to meet the demands of handling heavy goods and complex working conditions such as frequent starts and accelerations.

(2) Hangcha forklifts

Hangcha forklifts also hold an important position in the market, with reliable product performance and comfortable operation.

1. ** Light Electric Forklifts ** : For light forklifts of about 1-1.5 tons, such as some Hangcha 1-ton forklifts, the commonly compatible lead-acid batteries are 48V 200-300AH. This type of battery is relatively small in size and light in weight, which can well match the body design and power requirements of light forklifts, achieving a good balance between operational flexibility and endurance of the forklifts. It is suitable for some indoor storage environments where the mobility of forklifts is highly required and the weight of goods to be handled is relatively light.

2. ** Medium and Heavy-duty Electric Forklifts ** : For medium and heavy-duty Hangcha forklifts with a capacity of 2 to 5 tons, the battery specifications available are more diverse. These large-capacity and high-voltage batteries can provide strong power support for medium and heavy-duty forklifts, ensuring their stable operation when handling large and heavy goods and meeting the demands of high-intensity operations.

(3) Toyota Forklifts

Toyota forklifts are renowned worldwide for their advanced technology and outstanding quality.

1. ** Counterbalanced Forklift ** : In Toyota's counterbalanced forklift series, different tonnages are equipped with different lead-acid batteries. Commonly compatible with 48V batteries ranging from 300 to 500AH. This type of battery can meet the needs of forklifts for routine cargo handling in warehouses, factories and other places, and has good power performance and endurance. For medium-sized counterbalanced forklifts with a capacity of 3 to 5 tons, 48V 600-800AH or even higher capacity batteries may be adopted, or some models may be compatible with 80V voltage batteries to ensure that the forklift has sufficient power output when handling heavy goods and dealing with complex working environments.

2. ** Reach Trucks ** : Toyota reach trucks are mainly used for indoor warehousing and logistics, and have high requirements for the spatial adaptability and operational flexibility of the forklifts. The lead-acid battery it is compatible with is generally 48V 250-450AH. This type of battery, while ensuring the power demand of the forklift, can better adapt to the compact body structure of the reach truck due to its relatively small volume and weight, enabling the forklift to flexibly move through narrow shelf aisles and efficiently complete the handling and stacking of goods.

(4) Linde forklifts

Linde forklifts focus on the high-end forklift market and are renowned for their advanced technology and intelligent design.

1. ** Electric Pallet Truck ** : Linde's electric pallet trucks are compact and flexible, suitable for short-distance cargo handling. This type of vehicle is usually equipped with 24V or 48V lead-acid batteries, with a common capacity ranging from 150 to 300AH. It can meet the demand for frequent short-distance cargo handling within the warehouse. Moreover, the battery is relatively light in weight, easy to install and maintain, and the cost is relatively low at the same time.

2. ** Heavy-duty Forklifts ** : For Linde's heavy-duty forklifts, such as those used for handling large containers in ports, docks and other places, the power demand is extremely huge. This type of forklift often needs to be compatible with high-voltage and ultra-large-capacity lead-acid batteries. These super-large batteries can provide continuous and powerful power for heavy-duty forklifts, ensuring that the forklifts can stably handle goods weighing tens of tons in harsh working environments and meet the requirements of high-intensity and high-load operations.

3. Key Factors for Selecting Compatible Lead-Acid Batteries

(1) Working environment and Conditions of forklifts

1. ** Indoor environment ** : If the forklift mainly operates in indoor environments such as warehouses and supermarkets, due to the relatively enclosed space, higher requirements are placed on the safety and environmental friendliness of the battery. At this point, maintenance-free lead-acid batteries are a relatively ideal choice. Their sealed design can effectively reduce gas emissions, prevent indoor air pollution, and also lower the potential risk of damage to the ground and equipment caused by electrolyte leakage during maintenance. In addition, the indoor ambient temperature is relatively stable, and generally, there is no need to consider the performance of the battery at extreme temperatures.

2. ** Outdoor Environment ** : Forklifts operating outdoors may encounter complex climatic and environmental conditions such as high temperature, low temperature, humidity, and dust. In high-temperature environments, the self-discharge rate of batteries will increase, and the evaporation rate of the electrolyte will accelerate. Therefore, it is necessary to choose batteries with good heat dissipation performance and high-temperature resistance, and to strengthen the daily inspection and maintenance of batteries, and regularly replenish the electrolyte. In low-temperature environments, the capacity of batteries will decline and their starting performance will deteriorate. At this time, lead-acid batteries with good low-temperature performance should be selected, or heating devices should be equipped for the batteries to ensure their normal operation. For forklifts operating in damp and dusty environments, the protective performance of the battery is of vital importance. It is necessary to choose batteries with good sealing and protection levels to prevent moisture and dust from entering the battery interior, which could affect its performance and lifespan.

3. ** Work Intensity ** : If the forklift is used frequently, works for a long time every day, and often needs to handle heavy goods and perform frequent starting, accelerating and braking operations, this falls under high-intensity work conditions. In this case, it is necessary to select lead-acid batteries with large capacity and good high-current discharge performance to ensure that the forklift can maintain stable power output even under long-term and high-load working conditions. This can prevent the forklift's working efficiency from declining or even failing to operate normally due to insufficient battery capacity or poor discharge ability. On the contrary, if the forklift operation intensity is low, the usage frequency is not high, and the daily working hours are short, the requirements for battery capacity and discharge performance are relatively low. In such cases, a battery model with a smaller capacity and lower cost can be selected to reduce the procurement cost.

(2) Technical Parameters of Forklifts

1. ** Voltage Matching ** : The motor and control system of the forklift are designed for specific voltages, so the voltage of the selected lead-acid battery must be exactly matched with the rated voltage of the forklift. If the battery voltage is too high or too low, it may cause the forklift motor to fail to work properly, and even damage the motor and control system. Therefore, when choosing a battery, be sure to carefully check the technical manual of the forklift to confirm its rated voltage, and then select a battery with the corresponding voltage.

2. ** Capacity Adaptation ** : The battery capacity determines the forklift's endurance, that is, the time it can continue to work and the distance it can travel after a single charge. When choosing battery capacity, it is necessary to comprehensively consider factors such as the operation intensity of the forklift, the weight of the goods being moved, the length of the driving route, and whether there are slopes. Generally speaking, the greater the intensity of the work, the heavier the goods being handled, the longer the driving distance, and the more ramps there are, the greater the battery capacity required. The required battery capacity can be roughly estimated by calculating the average power consumption of the forklift within one working cycle and combining it with the number of working cycles per day. However, when making actual choices, a certain margin should also be taken into account to deal with possible special working conditions, such as long climbs and frequent starts.

3. ** Size and Weight Limitations ** : The battery installation space for forklifts is limited. The size of the selected lead-acid battery must be suitable for installation in the battery compartment of the forklift. At the same time, the impact of the battery's weight on the overall counterweight and stability of the forklift should be considered. If the battery size is too large to be installed in the battery compartment or if its installation affects the normal operation of other components of the forklift, then this battery is not suitable. In addition, an overly heavy battery may cause the forklift to have an unstable center of gravity, posing safety hazards during driving and handling goods. If the battery is too light, it may not meet the counterweight requirements of the forklift and will also affect the stability of the forklift. Therefore, when choosing batteries, it is necessary to accurately measure the size of the forklift battery compartment and understand the forklift's requirements for battery weight, and select batteries of appropriate size and matching weight.

(3) Battery Performance and Quality

1.** Cycle life ** : Cycle life refers to the number of times a battery can operate normally under certain charging and discharging conditions. The longer the cycle life is, the longer the battery's service life will be, and the lower the frequency of battery replacement will be, thereby reducing the usage cost. When choosing batteries, priority should be given to those with a long cycle life, especially for forklifts that are frequently used and have high operational intensity. Batteries with a long cycle life can significantly enhance their economic benefits.

2. ** Charging Acceptance capacity ** : Charging acceptance capacity reflects the battery's ability to quickly absorb electrical energy during the charging process. Batteries with strong charging acceptance capacity can complete charging in a relatively short time, reducing the downtime of forklifts and improving work efficiency. Especially when forklifts are frequently used and need to be recharged quickly, the ability to accept charging becomes particularly important. Some advanced lead-acid batteries adopt special plate materials and manufacturing processes, which can effectively enhance their charging acceptance capacity, enabling the battery to charge a large amount of electricity in a relatively short period of time.

3. ** Brand and Quality Assurance ** : Choosing lead-acid batteries from well-known brands usually leads to better quality assurance and after-sales service. Well-known brands have rich experience and advanced technology in battery research and development, production processes, quality control, etc. Their products are more reliable in quality and more stable in performance. Meanwhile, these brands often offer a longer warranty period. During this period, if the battery has quality problems, it can be repaired or replaced in a timely manner. In addition, the after-sales service networks of well-known brands are relatively complete, capable of providing users with timely and professional technical support and services, and solving various problems encountered by users during the usage process.