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In the modern logistics and warehousing industry, forklifts, as indispensable handling equipment, the normal operation of their power core - lead-acid batteries - directly determines the operational efficiency. However, due to frequent use, environmental factors and improper maintenance, lead-acid batteries are prone to various malfunctions. When a forklift stops working due to battery problems, mastering the necessary emergency repair skills and preparing the relevant tools in advance can quickly restore the equipment's operation and reduce the losses caused by downtime. This article will systematically introduce the emergency repair methods and key points of tool preparation for common faults of lead-acid batteries in forklifts, providing practical references for forklift users and maintenance personnel.

1. Analysis of Common Faults of Lead-Acid Batteries in ForkLifts

(1) Insufficient battery power or inability to charge

One of the most common faults is that a forklift suddenly experiences a drop in power during operation, fails to move normally, or is unable to store electricity when charging. The causes of such problems are diverse. It might be that the plates of the battery sulfate after long-term use, affecting the storage and release of electrical energy. It could also be a fault in the charging circuit, such as a loose charging plug, a damaged charging cable, or a faulty charger, which causes the current to be unable to be input normally. In addition, if the electrolyte inside the battery dries up and cannot form effective chemical reactions, it will also result in insufficient power or inability to charge.

(2) Plate vulcanization

Plate sulfation is a common problem in lead-acid batteries, manifested as the formation of white and hard lead sulfate crystals on the surface of the plates. Under normal circumstances, during the charging and discharging process of a battery, lead sulfate dissolves and precipitates on the plates. However, if the battery is frequently in an undercharged state, the density of the electrolyte is too high, or the liquid level is too low, lead sulfate will accumulate and crystallize on the plates, hindering the conduction of electrons and reducing the capacity and performance of the battery.

(3) Shell cracking and leakage

When forklifts are in operation, they may be subject to collision or compression, which can cause the battery casing to crack and subsequently lead to electrolyte leakage. The electrolyte contains sulfuric acid, which is highly corrosive. Once it leaks, it will not only cause damage to the forklift equipment but also pollute the environment and endanger the safety of the operators. In addition, leakage can also lead to a reduction in the electrolyte inside the battery, affecting its normal operation.

(4) Corrosion and poor contact of the terminal posts

The terminal post is a key part where the battery connects to the external circuit. During long-term use, the terminal post will undergo chemical reactions with moisture and acidic gases in the air, causing corrosion. After corrosion, a layer of oxide will form on the surface of the terminal post, increasing the contact resistance and causing poor current transmission, resulting in problems such as difficulty in starting the forklift and insufficient power.

2. Emergency Repair Skills

(1) Emergency handling for insufficient battery power or inability to charge

Check the charging circuit: First, carefully inspect whether the connection between the charging plug and the socket is firm, and whether there is any loosening or oxidation. If the plug is loose, reinsert it tightly and ensure good contact. If the plug or socket is oxidized, use sandpaper or a special metal cleaner to sand and remove the oxide. Next, check if the charging cable is damaged or broken. If so, you can temporarily wrap the damaged area with insulating tape or replace it with a new charging cable. If you suspect that the charger is faulty, you can try replacing it with a charger of the same model for a charging test.

Replenish the electrolyte: Open the liquid filling hole cover of the battery and check the height of the electrolyte level. If the liquid level is lower than the minimum mark, distilled water or special lead-acid battery replenishment fluid should be added. Be careful not to add tap water, as it contains impurities that can affect the performance of the battery. After adding the electrolyte, perform a low-current charge to ensure the electrolyte is fully mixed and observe whether the battery can regain its charging capacity.

Activate the plates: In cases where the battery power is insufficient or charging is impossible due to sulfation of the plates, the pulse repair method can be used for emergency treatment. By using a pulse repair instrument, high-frequency pulse current is output to break the lead sulfate crystals on the surface of the plates and restore the activity of the plates. In the absence of a pulse repair device, it is also possible to try charging with a small current for a long time to slowly activate the plates. However, this method is relatively slow in effect and may cause certain damage to the battery.

(2) Emergency Repair of Plate vulcanization

Chemical repair method: Completely drain the electrolyte from the battery, add dilute sulfuric acid solution, charge at a low current of 0.05-0.1A for 3-5 hours, then let it stand for 1-2 hours. Drain the electrolyte again, add distilled water, and repeat the above charging and standing steps until the sulfation phenomenon of the plates is improved. This method can dissolve the lead sulfate crystals on the surface of the plates, but it is necessary to pay attention to preventing the sulfuric acid solution from splashing out during the operation and take good protective measures.

Physical repair method: In addition to the pulse repair instrument mentioned earlier, the vibration repair method can also be adopted. Fix the battery on the vibration table and loosen and fall off the lead sulfate crystals on the surface of the plates through vibration. Physical repair methods are relatively safe, but their effects may not be as obvious as those of chemical repair methods.

(3) Emergency Treatment for Shell cracking and leakage

Temporary leak sealing: Once the battery casing is found to be cracked and leaking, the forklift should be stopped immediately, and the battery should be removed from the forklift and placed in a safe location. For smaller cracks, AB glue or epoxy resin glue can be used for repair. First, wipe the electrolyte around the crack clean, sand it rough with sandpaper, then apply glue, wait for the glue to cure, and check if there is still any leakage. For larger cracks, plastic or rubber sheets can be used. Cut them into appropriate shapes and glue them onto the cracks to seal the leaks.

Replace the casing: If the casing is severely cracked and cannot be repaired by temporary plugging, the battery casing should be replaced in time. When replacing, first completely drain the electrolyte from the battery, remove the terminal post connection plates, take out the plate group, place it in the new casing, then reinstall the terminal post connection plates and add new electrolyte. The process of replacing the casing is rather complicated and requires certain professional knowledge and skills. It is recommended that it be operated by professional maintenance personnel.

(4) Treatment of pole corrosion and poor contact

Clean the terminal post: Use sandpaper or a dedicated terminal post cleaning tool to thoroughly sand off the oxide on the surface of the terminal post to expose its metallic luster. At the same time, check whether the terminal post connection plates are also corroded. If so, clean them together. After the cleaning is completed, apply a layer of Vaseline or special conductive paste on the surface of the terminal post and connecting plate to prevent re-oxidation and enhance the conductive performance.

Tight connection: Check if the connecting bolts between the terminal post and the connecting plate are loose. If so, use a wrench to tighten the bolts to ensure a firm connection. When tightening the bolts, pay attention to applying moderate force to avoid damaging the terminal post due to excessive force. If the terminal post has suffered severe corrosion or deformation and cannot be repaired by cleaning and tightening, a new terminal post should be replaced in time.

3. Preparation of Emergency Maintenance Tools

(1) Basic Tools

Wrenches: including box wrenches, open-end wrenches and socket wrenches, are used for disassembling and installing battery terminal connection plates, casing fixing bolts, etc. For forklift batteries of different models, the specifications of the terminal post connection plates and bolts may vary. Therefore, it is necessary to prepare wrenches of various specifications to meet different maintenance requirements.

Screwdrivers: Cross-head screwdrivers and flat-head screwdrivers are indispensable tools for removing screws from the battery casing, as well as from components such as charging plugs and chargers.

Pliers: Pointed-nose pliers and diagonal pliers are also frequently used in maintenance processes. The point-nose pliers can be used to pick up small parts, such as gaskets, springs, etc. The diagonal pliers are used to cut wires, clean the oxide on the terminal posts, etc.

Multimeter: A multimeter is an important tool for testing the performance of circuits and batteries. The voltage of the battery, the charging current, the on-off state of the circuit, etc. can be measured by a multimeter, which helps to determine the cause of the fault. When choosing a multimeter, one should select a model with high precision and complete functions, such as a digital multimeter capable of measuring parameters like DC voltage, current, and resistance.

(2) Special tools

Electrolyte hydrometer: The electrolyte hydrometer is used to measure the density of the electrolyte in a storage battery. Through the density value, the charging state of the battery and whether the concentration of the electrolyte is normal can be determined. Pulse repair instrument: As mentioned earlier, the pulse repair instrument is a specialized tool for repairing sulfation on plates. It can effectively break the lead sulfate crystals on the surface of the plates and restore the performance of the battery. Although the price of the pulse repair instrument is relatively high, it is a very practical tool for enterprises or maintenance units that frequently use forklifts.

Charger: A spare charger is indispensable. When the battery fails to charge or the charging equipment malfunctions, using a backup charger can promptly charge the battery. When choosing a charger, it is necessary to select the appropriate model based on the capacity and voltage of the battery to ensure the charging effect and safety.

(3) Protective and auxiliary tools

Protective equipment: During the process of battery maintenance, corrosive electrolytes may come into contact. Therefore, it is necessary to prepare protective equipment such as acid and alkali resistant gloves, goggles, and aprons to ensure the safety of the operators.

Containers and funnels: Prepare some plastic containers for holding the drawn electrolyte; The funnel is used to add the electrolyte and prevent it from spilling out.

Cleaning supplies: Sandpaper, metal cleaner, rags and other cleaning supplies are used to remove oxides, dirt and electrolyte residues on components such as terminal posts and casings.

4. Precautions for Emergency Maintenance

Safety first: Before conducting battery maintenance, the main power switch of the forklift must be turned off to prevent electric shock accidents. During the operation, protective equipment should be worn properly to prevent the electrolyte from coming into contact with the skin and eyes. In case of accidental contact with the electrolyte, rinse immediately with plenty of water and seek medical attention promptly.

Correct operation: Strictly follow the maintenance steps and methods to avoid expanding the fault or damaging the battery due to improper operation. When disassembling and installing components, pay attention to the sequence and force to prevent damage to the parts.

Environmental protection treatment: The extracted electrolyte is classified as hazardous waste and cannot be discharged at will. It should be collected in dedicated containers and handed over to qualified units for treatment to protect the environment.

Regular maintenance: Emergency repair is only a temporary measure to solve sudden malfunctions and cannot replace daily maintenance and upkeep. Forklift users should regularly inspect and maintain the battery, such as checking the height of the electrolyte level, cleaning the terminals, and conducting charge and discharge tests, to extend the battery's service life and reduce the probability of faults.

In conclusion, mastering the emergency maintenance skills of lead-acid batteries in forklifts and making adequate tool preparations are of great significance for ensuring the normal operation of forklifts and improving the efficiency of logistics operations. Through the analysis of common faults and the study of corresponding maintenance methods, as well as the reasonable allocation of maintenance tools, forklift users and maintenance personnel can respond quickly and effectively solve problems when facing battery faults. At the same time, strengthening daily maintenance and upkeep, attaching importance to safe operation and environmental protection treatment will further enhance the reliability and service life of forklift lead-acid batteries, providing strong support for the production and operation activities of enterprises.