Troubleshooting Methods for Battery Forklift Batteries

The price of electric forklift batteries is expensive and an important component of electric forklifts. Once the main breakdown affects the daily production of the factory, the battery pack is the key to determining the working time, maintenance, and repair costs of forklifts. Generally, there are fewer problems with electric cars, but buying a battery with average quality products can cause a lot of complicated things in the future.

During use, the battery pack often experiences high or low voltage, high internal resistance, leakage, and deformation of the casing during operation. Based on the analysis of scrapped batteries and actual measurements, it can be known that the capacity of the battery pack during operation does not reach the nominal capacity, which is the most common phenomenon, leading to a shortened lifespan of the battery and early scrapping.

The actual service life of forklift batteries is influenced by two factors, internal and external. External factors mainly include overcharging, over discharging, environmental impact, and mismatched charging machines. Internal factors mainly include the reduction of moisture in the electrolyte. When the moisture in the battery decreases to a certain extent, it will cause the battery to fail.

In general, the electrolyte saturation in a battery should operate normally at a state greater than 95%. The data shows that if the saturation decreases from 95% to 85%, the battery capacity can be reduced by 20%. So internal factors are the direct cause of the decrease in battery capacity, indirectly affecting its lifespan. During the gradual reduction of moisture in the battery electrolyte, a series of phenomena such as high float charging voltage, high internal resistance, liquid leakage, and shell deformation often occur. In addition, during discharge, the deeper the discharge depth, the shorter the battery lifespan. The main harm of excessive discharge to the battery is that the active material on the positive electrode plate softens and loosens, the utilization rate decreases, and the lead sulfate generated during discharge cannot be restored during charging, resulting in a decrease in battery capacity.

In addition to the above analysis, we also need to know whether the contact terminals of the electric forklift battery are loose, and whether the output power of the motor increases, all of which need to be investigated one by one. There are two tools for battery maintenance in electric forklifts: one is a voltmeter, and the other is a hydrometer.