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In the modern logistics industry, forklifts are indispensable handling equipment, and lead-acid batteries, as the power source of forklifts, their performance directly affects the working efficiency and service life of forklifts. However, in the actual usage process, various faults are inevitable for forklift lead-acid batteries. Understanding these common faults and their solutions is of great significance for ensuring the normal operation of forklifts and reducing operating costs.

1. The battery power is insufficient or it cannot be charged

(1) Fault phenomenon

During the operation of the forklift, the driving distance is significantly shortened, the working time is greatly reduced, and the indicator light shows abnormal during charging, making it impossible to charge normally.

(2) Analysis of the cause of the fault

Plate sulfation: When a storage battery is in a state of low charge for a long time, the electrolyte level is too low, or the charging is insufficient, a layer of white and hard lead sulfate crystals will form on the surface of the plates, which is known as plate sulfation. This kind of crystallization will hinder the chemical reaction between the electrolyte and the plates, reducing the capacity and charging and discharging performance of the battery.

Charger failure: Damage to internal components of the charger, such as a blown fuse, short circuit in the circuit board, or transformer failure, can cause the charger to fail to output charging voltage and current normally, thus preventing it from charging the battery.

Charging circuit issues: Aging, damage, poor contact of the charging circuit, or loose or oxidized terminal blocks, etc., will cause an increase in the resistance of the charging circuit, a reduction or even interruption of the charging current, affecting the normal charging of the battery.

Battery aging: As the usage time increases, the active substances on the battery plates gradually decrease, the concentration of sulfuric acid in the electrolyte drops, and the capacity and performance of the battery will gradually decline, eventually leading to insufficient power and difficulty in charging.

(3) Solutions

Dealing with plate sulfation: For slightly sulfated batteries, a method of long-term charging with a small current can be adopted for repair. That is, use a current that is 1/2 to 1/3 lower than the normal charging current, charge continuously for 10 to 15 hours, then discharge and charge again. Repeat this process 2 to 3 times. For batteries with severe sulfation, a specialized battery repair instrument can be used to break the lead sulfate crystals through high-frequency pulse current and restore the activity of the plates. However, it should be noted that the performance of the repaired battery may not be fully restored to its initial state.

Inspect the charger: Check if the fuse of the charger is blown. If it is blown, replace it with a fuse of the same specification. Use a multimeter to test whether the output voltage and current of the charger are normal. If not, check whether the components on the circuit board are damaged, such as resistors, capacitors, diodes, etc., and replace the damaged components. If you do not have professional maintenance skills, it is recommended that you send the charger to a professional maintenance institution for inspection and repair.

Check the charging circuit: Carefully inspect the charging circuit for any signs of aging or damage. If so, replace the wires with new ones in a timely manner. Clean the oxide on the terminal blocks to ensure the wiring is firm and the contact is good. The surface of the terminal block can be sanded with sandpaper and then an appropriate amount of conductive paste can be applied to reduce the contact resistance.

Battery replacement: When the battery ages severely and still fails to meet the usage requirements after repair, a new battery should be replaced in a timely manner. When choosing a new battery, it is necessary to select a battery of appropriate capacity and specification based on the model and usage requirements of the forklift, and ensure its reliable quality.

2.The electrolyte of the battery is consumed too quickly

(1) Fault phenomenon

The electrolyte needs to be added frequently, and the intervals between additions are getting shorter and shorter.

(2) Analysis of the cause of the fault

Excessive charging current: If the output voltage of the charger is too high or the charging time is too long, it will cause the charging current of the battery to be too large, resulting in an electrolytic reaction of water in the electrolyte, generating hydrogen and oxygen, and thus causing a large amount of water in the electrolyte to be consumed.

Internal short circuit of the battery: Due to reasons such as plate deformation, separator damage, and active material shedding, the positive and negative plates inside the battery may come into direct contact, resulting in a short circuit. A short circuit will cause the battery to heat up, accelerate the evaporation and decomposition of the electrolyte, and result in the electrolyte being consumed too quickly.

Excessively high ambient temperature: In a high-temperature environment, the chemical reaction rate of the battery increases, and the evaporation rate of the electrolyte also significantly rises, resulting in the electrolyte being consumed too quickly.

(3) Solutions

Adjust the charging current: Check the Settings of the charger to ensure that its output voltage and current meet the specification requirements of the battery. If the charging current is too large, you can appropriately adjust the output parameters of the charger or replace it with a suitable one. At the same time, it is necessary to control the charging time well to avoid overcharging.

Check for internal short circuits in the battery: Open the battery casing and inspect whether the plates are deformed, whether the separators are damaged, and whether the active material has fallen off. If deformation of the plates is found, it should be corrected in time. If the partition is damaged, a new one needs to be replaced. Plates with severe shedding of active substances should be replaced. If the short circuit situation is rather complicated, it is recommended to send the battery to a professional maintenance institution for handling.

Improve the usage environment: Try to avoid forklifts working for long periods in high-temperature environments. If it is unavoidable, appropriate cooling measures can be taken, such as installing cooling fans around the battery or parking the forklift in a cool and well-ventilated area when taking a rest. At the same time, the liquid level of the electrolyte should be checked regularly, and distilled water or special battery replenishment fluid should be replenished in time.

3. The battery casing is swollen and deformed

(1) Fault phenomenon

The battery case shows obvious swelling, deformation and even cracking.

(2) Analysis of the cause of the fault

Overcharging or overcharging: Prolonged overcharging will cause a large amount of gas to be generated inside the battery. If these gases cannot be discharged in time, it will lead to an increase in the internal pressure of the battery, causing the casing to swell and deform.

Poor heat dissipation: During the charging and discharging processes of the battery, heat is generated. If the heat dissipation conditions are poor, such as poor ventilation around the battery or blocked heat dissipation holes, heat accumulation will occur, causing the internal temperature of the battery to rise and the pressure to increase, which in turn leads to the swelling of the casing.

Quality issue: Some batteries have inherent quality defects due to poor production processes, substandard material quality, and other reasons. During use, they are prone to problems such as shell swelling and deformation.

(3) Solutions

Standard charging operation: Charge strictly in accordance with the battery's user manual, control the charging time and current well, and avoid overcharging. A charger with intelligent charging function can be used. It can automatically adjust the charging parameters according to the state of the battery to prevent overcharging.

Improve heat dissipation conditions: Regularly clean the dust and debris on the battery casing to ensure that the heat dissipation holes are unobstructed. Check whether the installation location of the battery is well-ventilated. If the ventilation is poor, you can consider adjusting the installation location or adding ventilation facilities. At the same time, avoid placing the battery near heat sources, such as engines.

Replace the battery with a reliable one: If the casing swells and deforms due to battery quality issues, stop using the battery immediately and replace it with a new one of reliable quality. When purchasing storage batteries, choose products made by regular manufacturers and check the quality certification and relevant test reports of the products.

4. The output voltage of the battery is unstable

(1) Fault phenomenon

During the operation of the forklift, the power is sometimes strong and sometimes weak, and the voltage display on the instrument panel is unstable, fluctuating up and down.

(2) Analysis of the cause of the fault

Shedding of active substances on the plates: During the long-term use of the battery, the active substances on the plates will gradually fall off and deposit at the bottom of the battery. When a large amount of active material falls off, it will lead to poor contact between the plates, thereby causing unstable output voltage.

Loose or oxidized connection wires: If the connection wires of the battery are loose or oxidized, it will increase the contact resistance of the circuit, causing unstable current transmission and subsequently leading to fluctuations in the output voltage.

Internal single cell failure of the battery: A battery is composed of multiple single cells. If a single cell fails, such as a short circuit or open circuit of the plates, it will affect the output voltage of the entire battery, making it unstable.

(3) Solutions

Dealing with the shedding of active substances on the plates: Open the battery casing and clean the active substances deposited at the bottom thoroughly. For the plates with mild detachment, they can continue to be used. If the detachment is severe, new plates should be replaced. During the cleaning process, it is necessary to pay attention to avoiding the entry of active substances into other cells, which may affect the performance of other cells.

Check and tighten the connection wires: Check if the connection wires of the battery are loose. If any are loose, use a wrench to tighten them. At the same time, check whether the terminals of the connecting wires are oxidized. If there is oxidation, sand it clean with sandpaper and then apply an appropriate amount of conductive paste to ensure a good connection.

Detection and repair of single-cell faults: Use a multimeter to measure the voltage of each cell in the battery. If the voltage of a certain cell is significantly lower than that of the others, it indicates that there is a fault in that cell. For single cells with short-circuited plates, attempts can be made to replace the separators or plates for repair. For open cells, the open point needs to be located and repaired. If it cannot be repaired, the entire cell should be replaced.

5. Summary

Common faults of forklift lead-acid batteries include insufficient power or inability to charge, rapid consumption of electrolyte, bulging and deformation of the casing, and unstable output voltage, etc. The causes of these malfunctions are diverse, involving multiple aspects such as the quality of the battery itself, usage and maintenance methods, and the working environment. In the actual usage process, we should strengthen the daily maintenance and care of the battery, regularly check the liquid level height and density of the electrolyte, the working condition of the charging equipment, and the tightness of the connecting wires, etc. Once a fault is detected, the cause should be analyzed promptly and accurately, and corresponding solutions should be taken to handle it. Only in this way can the service life of the battery be prolonged, the working efficiency of the forklift be improved, and the operating costs of the enterprise be reduced. Meanwhile, with the continuous development of technology, new battery technologies are constantly emerging. Enterprises can consider adopting new technologies and products in a timely manner based on their own actual situations to further enhance the performance and reliability of forklifts.