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Abstract

This article elaborates in detail the key points of the electrolyte in forklift lead-acid batteries during the maintenance and replacement process, introduces the composition and function of the electrolyte, analyzes the items and methods that need attention in daily maintenance, and discusses the timing, steps and precautions for electrolyte replacement. It aims to help forklift users and maintenance personnel better understand and master the relevant knowledge of lead-acid battery electrolyte, improve the service life and working performance of the battery, and ensure the normal operation of forklifts.

1. Introduction

Forklifts, as indispensable handling equipment in modern logistics and warehousing industries, mainly rely on lead-acid batteries for power. The performance and service life of lead-acid batteries have a direct impact on the working efficiency and operating costs of forklifts. As the key substance for electrochemical reactions occurring inside lead-acid batteries, the state of the electrolyte directly affects the charging and discharging performance of the battery. Therefore, it is of vital importance to do a good job in the maintenance and replacement of the electrolyte in forklift lead-acid batteries. Through reasonable maintenance and correct replacement, the service life of the battery can be effectively prolonged, the probability of equipment failure can be reduced, the overall operational efficiency of forklifts can be improved, and operating costs can be saved for enterprises.

2. Composition and Function of Electrolyte in Forklift Lead-Acid Batteries

(1) Composition

The electrolyte of forklift lead-acid batteries is mainly composed of sulfuric acid and distilled water mixed in a certain proportion. Sulfuric acid exists in the electrolyte in ionic form, providing the necessary ionic environment for the electrochemical reactions inside the battery. Distilled water plays a role in diluting sulfuric acid and regulating the density of the electrolyte. It is also an indispensable participant in electrochemical reactions. In the newly configured electrolyte, the mass fraction of sulfuric acid is usually around 30% to 40%, and the specific proportion may vary depending on different types and specifications of lead-acid batteries.

(2) Function

1. ** Electrochemical Reaction medium ** : During the charging and discharging process of lead-acid batteries, the electrolyte participates in a series of complex chemical reactions. When charging, sulfuric acid reacts with substances on the plates, converting electrical energy into chemical energy for storage. During discharge, chemical energy is converted back into electrical energy through the action of the electrolyte, providing power for the forklift. For instance, during the discharge process, the lead at the negative electrode reacts with the sulfuric acid in the electrolyte to form lead sulfate and electrons. The electrons pass through the external circuit to generate a current, driving the forklift to operate.

2. ** Conducting Current ** : The ions in the electrolyte serve as the carriers for current conduction, capable of forming ionic conductive paths within the battery, allowing the current to flow smoothly between the positive and negative plates and ensuring the normal charging and discharging process of the battery.

3. ** Regulating Electrode Potential ** : Appropriate electrolyte composition and concentration help maintain a stable electrode potential, ensuring the smooth progress of electrochemical reactions and enhancing the charging and discharging efficiency and performance of the battery.

3. Key Points for Daily Maintenance of Lead-acid Battery Electrolyte in Forklifts

(1) Check the electrolyte level

1. ** Inspection Frequency ** : For frequently used lead-acid batteries of forklifts, it is recommended to conduct an electrolyte level check once before daily operation; Even if the usage frequency is low, it should be checked at least once a week.

2. ** Inspection Method ** : Open the liquid injection hole cover on the battery and observe the electrolyte level. Under normal circumstances, the electrolyte level should be 10 to 15 millimeters above the top of the plates or within the liquid level scale range marked on the battery case. If the liquid level is too low, the plates will be exposed to the air, causing sulfation of the plates and reducing the capacity and service life of the battery. If the liquid level is too high, it may cause the electrolyte to overflow during the charging process, corroding the battery casing and other components of the forklift.

3. ** Liquid Level Replenishment ** : When the electrolyte level is found to be too low, distilled water or dedicated lead-acid battery replenishment fluid should be replenished in a timely manner. It is strictly prohibited to use tap water or other water containing impurities, as the minerals and other impurities in tap water will mix into the electrolyte, affecting the progress of electrochemical reactions and accelerating the aging and damage of the battery. When replenishing the liquid, it should be added slowly to avoid splashing, and at the same time, be careful not to exceed the specified upper limit of the liquid level.

(2) Detection of electrolyte density

1. ** Detection Frequency ** : Generally, the electrolyte density should be tested once every two weeks. When the battery is frequently used, the ambient temperature fluctuates greatly, or the battery's performance declines, the detection frequency should be appropriately increased.

2. ** Detection tools ** : Use a dedicated hydrometer (such as a float hydrometer) for detection. Insert the hydrometer into the liquid injection hole, draw in an appropriate amount of electrolyte to make the float float up, and read the scale value on the float that is level with the liquid surface, which is the density of the electrolyte.

3. ** Standard Range ** : At 25℃, the normal density range of the electrolyte is generally between 1.24 and 1.30g/cm³. There may be slight differences among different brands and specifications of batteries. If the detected density value is not within the normal range, adjustments need to be made according to the specific situation. When the density value is too high, distilled water can be added appropriately for dilution. When the density value is too low, it may be necessary to add a special sulfuric acid solution to increase the density. However, the operation of adding sulfuric acid solution is rather complicated and has certain risks. It is recommended that it be carried out by professionals.

4. ** Temperature Correction ** : The density of the electrolyte varies with temperature. For every 1℃ increase in temperature, the density decreases by approximately 0.0007g/cm³. For every 1℃ decrease in temperature, the density increases by approximately 0.0007g/cm³. Therefore, when detecting the density of the electrolyte, the measured values need to be corrected according to the actual temperature.

(3) Visual Inspection

1. ** Inspection Content ** : Regularly check whether the battery casing is damaged or leaking, and whether the liquid injection hole cover is well sealed. Observe the color and transparency of the electrolyte. A normal electrolyte should be clear and transparent, colorless or light yellow. If the electrolyte becomes turbid, black or has flocculent substances, it may indicate that there is sulfation of the plates, short circuit or other faults inside the battery, and further inspection and treatment are required.

2. ** Handling Method ** : Once the battery casing is found to be damaged or leaking, the battery should be immediately stopped from use and replaced to prevent electrolyte leakage from causing harm to the environment and personnel. If the electrolyte shows abnormal color or condition, the battery should be sent to a professional maintenance institution for inspection and repair.

(4) Maintenance during Charging

1. ** Control charging current and voltage ** : When charging the lead-acid battery of a forklift, the appropriate charging current and voltage should be set strictly in accordance with the battery's user manual and the charger's operating procedures. Excessive charging current will cause the temperature of the electrolyte to rise too quickly, accelerating the evaporation of water and the aging of the plates. A charging current that is too small will prolong the charging time and affect the normal use of the forklift. Under normal circumstances, the charging current should not exceed 10% of the rated capacity of the battery.

2. ** Monitor charging temperature ** : During the charging process, closely monitor the temperature of the electrolyte. When the temperature exceeds 45℃, charging should be suspended and resumed only after the temperature drops. Excessively high temperatures will cause a large amount of water in the electrolyte to evaporate, accelerating the corrosion of the plates and the shedding of active substances, thereby reducing the performance and lifespan of the battery. Ventilation and heat dissipation, cooling devices and other methods can be adopted to reduce the temperature during the charging process.

3. ** Avoid overcharging and undercharging ** : Overcharging can cause excessive decomposition of the electrolyte, generating a large amount of gas and heat, leading to plate deformation and active material shedding; Undercharging will prevent the battery capacity from being fully restored, resulting in sulfation of the plates. Therefore, the charging time should be reasonably set according to the capacity and usage of the battery to ensure that the battery can be fully charged without overcharging.

4. Key Points for Replacing Electrolyte in Forklift Lead-Acid Batteries

(1) Judgment of Replacement Timing

1. ** Severe deterioration of electrolyte ** : When the electrolyte shows severe deterioration such as turbidity, blackening, pungent smell or a large amount of flocculent substances, and cannot be restored to normal through adjustment after testing, the electrolyte needs to be replaced.

2. ** Density cannot be adjusted ** : If the density of the electrolyte still cannot reach the normal range after multiple adjustments, it indicates that the components in the electrolyte have undergone irreversible changes. At this point, it is necessary to consider replacing the electrolyte.

3. ** Significant decline in battery performance ** : Under normal maintenance conditions, the capacity of the forklift's lead-acid battery drops significantly, and the usage time after charging is greatly shortened. After ruling out other fault causes, it may be due to the aging of the electrolyte, and the electrolyte also needs to be replaced.

4. ** Excessive usage time ** : Generally speaking, the performance of the electrolyte in forklift lead-acid batteries will gradually decline after 2 to 3 years of use. To ensure the normal operation of the battery, it is recommended to replace it.

(2) Preparations before Replacement

1. ** Tool and Material Preparation ** : Prepare protective gloves, goggles, acid-resistant containers, funnels, distilled water, special sulfuric acid solution (as needed), hydrometer and other tools and materials. At the same time, it is necessary to ensure that the site for the change is well-ventilated and kept away from fire sources and flammable materials.

2. ** Battery Discharge ** : Before replacing the electrolyte, the battery should be discharged appropriately to reduce its charge level to a relatively low level. This can reduce the intensity of chemical reactions during the replacement process and lower the probability of danger occurring.

3. ** Clean the battery ** : Wipe the battery casing with a damp cloth to remove surface dust, dirt and residual electrolyte to prevent these impurities from entering the battery during the electrolyte replacement process.

(3) Replacement Steps

1. ** Discharge of old electrolyte ** : Carefully open the liquid filling hole cover of the battery, place the acid-resistant container under the battery, and use a siphon or other suitable tool to slowly draw out or pour the old electrolyte into the container. Note that the operation should be slow and steady to avoid splashing the electrolyte. During the discharge process, it is necessary to ensure that all the old electrolyte is collected and must not be dumped at will, as the used electrolyte contains harmful substances such as sulfuric acid, which will cause serious pollution to the environment.

2. ** Cleaning the battery ** : Add an appropriate amount of distilled water to the battery, gently shake it to ensure the distilled water thoroughly rinses the plates and the internal space, and then drain the cleaned water. Repeat the cleaning 2 to 3 times until the discharged water is clear and transparent. The cleaning process can effectively remove the residual impurities and used electrolyte inside the battery, creating favorable conditions for the addition of new electrolyte.

3. ** Add new electrolyte ** : According to the specifications and instructions of the battery, use a funnel to slowly add the newly prepared electrolyte to the battery until the electrolyte level reaches the specified height. When adding the electrolyte, pay attention to controlling the speed to avoid the electrolyte overflowing. At the same time, it is necessary to ensure that the density of the new electrolyte meets the requirements. If the density needs to be adjusted, it should be done before adding the electrolyte.

4. ** Standing and Testing ** : After adding new electrolyte, let the battery stand for 1-2 hours to allow the electrolyte to fully penetrate the plates. Then use a hydrometer to measure the density of the electrolyte and make adjustments as needed. At the same time, check whether the electrolyte level is normal. If necessary, replenish it appropriately.

(4) Precautions after Replacement

1. ** Sealing and Fixation ** : After confirming that the electrolyte level and density are normal, seal the liquid injection hole cover well to ensure that there will be no electrolyte leakage. At the same time, fix the battery in the correct position on the forklift to ensure it is installed firmly and avoid damage due to vibration during the operation of the forklift.

2. ** Initial Charging ** : After the electrolyte has been replaced, the battery needs to be charged for the first time. The charging current and time should be set according to the battery's user manual. During the initial charging process, closely monitor the changes in the battery's temperature, voltage and electrolyte. If any abnormality is detected, stop charging immediately and conduct an inspection.

3. ** Follow-up Observation ** : During the period after the electrolyte is replaced, it is necessary to strengthen the observation and inspection of the battery. Check the electrolyte level and density every day to observe whether the charging and discharging performance of the battery has improved. If problems with the battery are still found, professional personnel should be contacted in time for further inspection and repair.

5. Conclusion

The maintenance and replacement of the electrolyte in forklift lead-acid batteries is a key link to ensure the normal operation of the batteries and extend their service life. Through strict maintenance of the electrolyte level, density, appearance and charging process on a daily basis, problems existing in the electrolyte can be detected and solved in a timely manner, maintaining the good performance of the battery. Replacing the electrolyte at the right time and following the correct replacement steps and precautions can effectively restore the performance of the battery and reduce the occurrence of faults. Forklift users and maintenance personnel should fully recognize the significance of electrolyte maintenance and replacement, master relevant knowledge and skills, ensure that the lead-acid batteries of forklifts are always in good working condition, provide reliable power support for the logistics and warehousing operations of enterprises, reduce operating costs, and improve economic benefits. At the same time, during the maintenance and replacement of the electrolyte, safety precautions should always be taken, and the disposal of used electrolyte should be properly handled to protect the environment and personnel health.