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In the modern logistics and warehousing industry, forklifts, as indispensable handling equipment, their operational efficiency directly affects the production and operation costs of enterprises. As the "heart" of a forklift, the lead-acid battery is the core source of its power. The performance and service life of the battery are closely related to the daily maintenance and care work. Scientific and reasonable maintenance and care of forklift lead-acid batteries can not only ensure the stable and efficient operation of forklifts, but also effectively reduce the equipment replacement costs of enterprises and improve economic benefits. This article will elaborate in detail on the maintenance and care skills of forklift lead-acid batteries from multiple dimensions, providing comprehensive and practical references for enterprise equipment managers and forklift operators.

1. Understanding Forklift lead-acid Batteries

Before delving into maintenance and care techniques, it is necessary to first understand the basic structure and working principle of forklift lead-acid batteries. Forklift lead-acid batteries are mainly composed of plates, separators, electrolyte, casings and other parts. The plates are divided into positive plates and negative plates. The active material on the positive plate is lead dioxide, and the active material on the negative plate is spongy pure lead. The partition is used to separate the positive and negative plates to prevent short circuits. The electrolyte is prepared by mixing pure sulfuric acid and distilled water in a certain proportion.

Its working principle is based on electrochemical REDOX reactions. During the discharge process, the active substances on the positive and negative plates react with sulfuric acid in the electrolyte, converting chemical energy into electrical energy to provide power for the forklift. During the charging process, electrical energy is input through an external power source to restore the active substances on the positive and negative plates to their initial state, achieving the conversion of electrical energy into chemical energy. Understanding these fundamental principles helps us better comprehend the impact of maintenance work on the performance of storage batteries.

2. Key Points for Daily Use and Maintenance

(1) Charging Management

The correct charging timing: Avoiding excessive discharge is the key to extending the battery life. Generally speaking, when the battery voltage drops to about 80% to 85% of the rated voltage, it should be charged in time. Excessive discharge can lead to sulfation of the plates, causing the formation of insoluble lead sulfate crystals on the plate surface, which seriously affects the charging and discharging performance and service life of the battery. At the same time, frequent shallow discharges followed by immediate charging should also be avoided, as this may lead to the memory effect of the battery and reduce its overall performance.

Select the appropriate charger: Different models and specifications of forklift lead-acid batteries need to be matched with corresponding chargers. The voltage and current parameters of the charger must be in line with the rated parameters of the battery. Using an unmatched charger may result in insufficient charging or overcharging. Overcharging will raise the temperature of the electrolyte, accelerate the evaporation of water, and cause the plates to deform and the active substances to fall off. Insufficient charging will accelerate the sulfation of the plates.

Charging environment and process monitoring: The charging site should be well-ventilated and kept away from fire sources and flammable materials, as the battery will produce flammable and explosive gases such as hydrogen during the charging process. During the charging process, it is necessary to regularly check the temperature of the electrolyte. When the temperature exceeds 45℃, charging should be suspended and resumed only after the temperature drops to prevent damage to the battery due to high temperature. At the same time, observe the changes in charging current and voltage. If abnormal fluctuations occur, the cause should be investigated in a timely manner.

(2) Electrolyte Management

Regularly check the electrolyte level: The level of the electrolyte directly affects the performance of the battery. Under normal circumstances, the electrolyte level should be 10 to 15mm higher than the top of the plates. When the liquid level is too low, the plates will be exposed to the air, causing oxidation and sulfation of the plates and shortening the battery life. 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. It is recommended that the inspection frequency be at least once a week. For frequently used forklifts, the inspection frequency can be appropriately increased.

Correct addition of electrolyte: When it is found that the electrolyte level is insufficient, distilled water or special lead-acid battery replenishment liquid should be added. It is strictly forbidden to add sulfuric acid solution. During the operation of the battery, the moisture content will decrease due to evaporation and electrolysis, while the content of sulfuric acid remains relatively stable. Adding sulfuric acid will disrupt the original proportion of the electrolyte and affect the performance of the battery. When adding the electrolyte, it should be injected slowly to avoid the formation of bubbles and splashing.

Monitoring the density of the electrolyte: The density of the electrolyte is an important indicator reflecting the charging status and performance of the battery. Generally speaking, when fully charged, the density of the electrolyte is around 1.28g/cm³ at 25℃. As the discharge process progresses, the density will gradually decrease. Regularly measuring the density of the electrolyte with a hydrometer can help you promptly understand the charging and discharging conditions of the battery. If abnormal density is found, the cause should be analyzed to determine whether there are problems such as insufficient charging and sulfation of the plates, and corresponding solutions should be taken.

(3) Cleaning and Inspection

Surface cleaning: Regularly clean the surface of the battery casing to remove dust, oil stains and electrolyte residues. These impurities may cause leakage of the battery casing, affecting its performance and safety. When cleaning, you can use a damp cloth to wipe. Avoid using organic solvents to prevent damage to the casing. At the same time, check if there are any cracks or damages on the battery casing. If there are any problems, replace it in time to prevent the leakage of the electrolyte.

Inspection of terminal posts and connecting wires: Check if the terminal posts are loose, oxidized or corroded. Loose poles can lead to poor contact, affecting current transmission and causing difficulty in starting the forklift or insufficient power. Oxidation and corrosion can increase contact resistance, cause heating, and in severe cases, may lead to fires. For minor oxidation and corrosion, the surface of the terminal post can be sanded with sandpaper, and then a special anti-oxidation protective agent can be applied. If the terminal post is severely damaged, a new terminal post or connecting wire needs to be replaced. In addition, regularly check whether the connecting wires are firm and whether there is any damage or aging. Replace the faulty connecting wires in time.

3. Key Points of Seasonal Maintenance and Upkeep

(1) Summer maintenance

In summer, the temperature is relatively high, and the evaporation rate of the electrolyte increases, making the battery more prone to water shortage. Therefore, in summer, the frequency of checking the electrolyte level should be increased, and distilled water or supplementary liquid should be replenished in a timely manner. At the same time, high temperatures will accelerate the chemical reaction rate inside the battery, generating more heat during the charging process, which can easily lead to an excessively high temperature of the electrolyte. Therefore, it is necessary to strictly control the charging time and current to avoid overcharging. During the charging process, strengthen the monitoring of the electrolyte temperature. Once the temperature exceeds 45℃, immediately take cooling measures, such as suspending charging and ventilating for heat dissipation.

(2) Winter maintenance

In winter, when the temperature is low, the fluidity of the electrolyte deteriorates and its density increases, which will affect the capacity and discharge performance of the battery. Before the arrival of winter, the density of the electrolyte should be checked and appropriately increased to enhance the low-temperature performance of the battery. At the same time, it is necessary to ensure that the battery is fully charged, as a battery in a depleted state is more likely to freeze in low-temperature environments, damaging the plates and casing. If the forklift is not used for a long time, the battery should be removed and stored in a warm and dry room, and replenished regularly. In addition, before starting the forklift, the battery can be preheated appropriately, such as by using an insulation cover or charging it slowly, to enhance its activity.

4. Fault Prevention and Handling

(1) Prevention of Common Faults

Prevention of plate sulfation: Plate sulfation is one of the common faults of forklift lead-acid batteries, mainly caused by excessive discharge, long-term insufficient charging or excessively high electrolyte density. To prevent sulfation of the plates, it is necessary to strictly follow the charging regulations, avoid excessive discharge, and regularly perform deep discharge and full charging to activate the active substances on the plates. Meanwhile, keep the density of the electrolyte within the normal range and conduct regular inspections and adjustments.

Self-discharge prevention: Self-discharge of storage batteries is inevitable, but if the self-discharge phenomenon is severe, it will affect its normal use. Self-discharge is mainly caused by reasons such as unclean battery surfaces, impure electrolyte or internal short circuits. Therefore, it is necessary to keep the surface of the battery clean, use high-purity electrolyte, and regularly check whether there is a short circuit inside the battery to eliminate faults in a timely manner.

(2) Common Fault Handling

Capacity decline: If you find that the battery capacity has significantly decreased, first check whether the charging is sufficient and whether the charging process is normal. If the charging is normal, it might be caused by sulfation of the plates or the shedding of active substances. For mild sulfation of the plates, repair can be carried out by charging with a small current for a long time or by using the method of de-sulfation charging. For batteries with severe shedding of active substances, the plates or the entire battery need to be replaced.

Charging heat generation: During the charging process, the battery gets hot, which may be caused by excessive charging current, insufficient electrolyte or internal short circuit. Charging should be stopped immediately. Check whether the charging current meets the requirements and whether the electrolyte level is normal. If the electrolyte is insufficient, add distilled water and continue charging. If an internal short circuit is suspected, the battery should be disassembled for inspection to identify the short circuit point and repair or replace the damaged components.

In conclusion, the maintenance and care of lead-acid batteries in forklifts is a meticulous and crucial task, involving all aspects of daily use as well as the special requirements of different seasons. Only by strictly adhering to maintenance and care norms, strengthening daily inspection and management, and promptly preventing and handling faults, can we ensure that the lead-acid batteries of forklifts always maintain good performance, extend their service life, provide reliable power support for the logistics and handling work of enterprises, reduce operating costs, and improve production efficiency.