During peak season, you're busy stocking up, but your forklift suddenly breaks down; your newly replaced lead-acid battery bulges and leaks after only two months—are these your daily problems?

Actually, these forklift battery quirks can be resolved with proper maintenance! Following this scientific maintenance method can not only extend battery life by 50%, but also save you nearly 10,000 yuan a year in replacement and repair costs. Save this and learn it now! First, a reminder: data shows that 72% of forklift malfunctions are due to improper lead-acid battery maintenance! "Using the battery completely until it's completely off before charging," "plugging it in immediately after finishing work," and "never checking the electrolyte level"—these seemingly convenient practices are all culprits in damaging batteries. Even more dangerous is the hidden safety hazard—electrolyte leaks can burn the skin, and hydrogen fumes accumulated during charging can have disastrous consequences if exposed to an open flame.

battery

"A 5-minute daily 'health check-in' can reduce battery malfunctions by 90%." First, clean the battery surface and terminals with a dry cloth for a basic cleaning. If you find any sticky electrolyte residue, a 5% baking soda solution will neutralize the problem. A weekly "deep check-up" is essential—open the filler cap to check the electrolyte level, ensuring it's 10-15mm above the plates. This prevents the plates from being exposed and oxidized, and also avoids overfilling, which could cause overflow during charging. Additionally, check the terminals for heat and look for bulges or cracks in the casing. If any abnormalities are found, stop charging immediately and consult a mechanic to prevent small problems from becoming major malfunctions.

The charging process is the "critical battleground" for maintenance and the "core secret" to extending battery life. Don't wait until the battery is "starved" before charging. When the dashboard shows 20%-30% charge remaining, it's the optimal time to recharge. Batteries that have just finished charging are "overheating." Don't plug them in immediately; let them sit for 30 minutes to "cool down" before charging. Before charging, be sure to open all electrolyte filler plugs to allow the generated hydrogen gas to "breathe freely." The charging area should be well-ventilated and kept away from open flames, welding equipment, and other "dangerous partners." The charger must be "precisely matched" to the battery; avoid using the wrong charger. Disconnect the power promptly after charging is complete. Stop charging after 8-10 hours of "full charging." Overcharging for more than 12 hours is most likely to cause battery bulging.

battery-charger

Electrolyte replenishment is a "confusion point" for many companies. Here is the "standard answer": only add distilled water or dedicated deionized water; anything else is "troublesome"! Tap water and mineral water contain impurities that can cause internal short circuits and battery failure; adding electrolyte arbitrarily will change the concentration and "corrode the plates." Add electrolyte only after charging is complete, filling to the "maximum mark" on the casing. Avoid overfilling. Especially in high-temperature environments such as workshops, where electrolyte "evaporates quickly," frequent observation and replenishment are necessary to ensure the battery is always "fully hydrated."

If you'd like even more convenience, we also offer an automatic water replenishment system for your selection.

Automatic water replenishment system

During off-seasons or equipment maintenance, extra care is needed during battery "idle periods." For short-term storage (1-3 months), ensure the battery is fully charged before use, and recharge monthly to maintain over 80% operational capacity. For long-term storage (over 3 months), in addition to fully charging, it is recommended to disconnect the terminals, clean the surface, and tighten the electrolyte plug, recharging every 2 months. Store in a dry, well-ventilated environment with a temperature between 5-25℃, avoiding direct sunlight, freezing temperatures, and other harsh conditions to prevent battery cracking. Special reminder: Always wear protective gloves and goggles during maintenance. If electrolyte accidentally comes into contact with skin, immediately rinse with plenty of water. Seek medical attention immediately if the condition is severe; safety is always the top priority.

For special scenarios such as low temperatures in cold storage and high temperatures in workshops, we also have specific techniques: In low-temperature environments, allow the battery to stand at room temperature for 1 hour before charging to avoid low charging efficiency; in high-temperature operations, in addition to frequently adding distilled water, ensure good ventilation and heat dissipation to prevent the battery from overheating. In case of emergencies such as sudden battery bulging or leakage, first disconnect the power to isolate the battery, then use dry sand to absorb the leaking liquid. Never rinse directly with water.

Lead-acid batteries are the "power heart" of forklifts, and their stable operation is the "cornerstone" of efficient production for enterprises. Seemingly simple maintenance details are actually "key levers" for cost reduction and efficiency improvement. Making scientific maintenance an industry consensus, and ensuring that every forklift can operate with full power on the front lines, will inject stronger momentum into the high-quality development of the logistics industry.