In the wave of iterative upgrades to forklift power systems, the maintenance standards of lead-acid batteries, as a widely used traditional power source, remain a core concern for industrial enterprises. By establishing a systematic and meticulous maintenance system, the average lifespan of lead-acid batteries can be extended from 1.2 years to 2.5 years, reducing the average annual maintenance cost per forklift.

Although the application share of lithium batteries in forklift power is gradually increasing, lead-acid batteries still dominate the forklift power market due to their low cost, strong adaptability, and convenient maintenance, especially in small and medium-sized logistics companies and short-distance handling scenarios. However, data shows that improper maintenance leads to premature failure of lead-acid batteries in as many as 45% of cases.

The lifespan degradation of lead-acid batteries is not irreversible. In most cases, it is caused by the accumulation of problems such as improper electrolyte management, incorrect charging methods, and environmental factors. By mastering scientific maintenance methods, their lifespan can be significantly extended.

Key Maintenance Points: Six Key Steps to Create Long-Life Batteries To achieve long-term use of forklift lead-acid batteries, six core maintenance steps must be strictly followed, forming a complete management cycle of "daily inspection—standardized charging—regular maintenance—troubleshooting."

Electrolyte Management: This is the most important aspect of lead-acid battery maintenance. Before each charge, check that the electrolyte level is between the "maximum" and "minimum" marks on the battery casing. If the level is below the minimum mark, add distilled water immediately (never add tap water, mineral water, or electrolyte; impurities in tap water will corrode the plates, and adding extra electrolyte will lead to excessive sulfuric acid concentration, accelerating plate sulfation).

Tips: The electrolyte density should be checked quarterly to ensure it is between 1.26-1.28 g/cm³. If the density is abnormal, please contact a professional for adjustment. Charging Standards: Avoiding both over-discharge and under-charge is crucial. Charge the forklift battery immediately when it reaches 20%-30% charge. Never fully discharge the battery before charging, as this will cause deep sulfation of the plates, making it difficult to restore capacity.

Use a dedicated charger compatible with the battery and keep the charging time between 8-10 hours. Disconnect the power supply immediately after charging to avoid overcharging (overcharging generates a large amount of gas, leading to electrolyte leakage and battery swelling).

Maintain good ventilation during charging, keeping the temperature between 15-30℃.

Avoid charging in direct sunlight during summer. Preheat the battery for 1 hour before charging in winter to prevent reduced charging efficiency at low temperatures.

Terminal Maintenance: Wipe the battery terminals weekly with a dry cloth to remove oxides and dust. If corrosion is found, clean with a 5% baking soda solution, allow it to dry, and then apply petroleum jelly to prevent oxidation and rust. Ensure good contact to avoid reduced charging efficiency or short circuits due to poor contact.

**Casing Inspection:** Before and after each use, inspect the battery casing for damage or leaks. If cracks or electrolyte leaks are found, immediately stop using the battery, replace it, and clean the leaking area (the electrolyte is corrosive; wear protective gloves and a mask, and neutralize with baking soda solution before wiping). This will prevent leaks from damaging other parts of the forklift.

**Regular Equalization Charging:** After every 30 regular charges, perform an equalization charge (i.e., "completing the charge"). This involves charging with a low current for 2-3 hours after a normal charge to ensure consistent voltage across all cells. This prevents over-discharge of some cells due to voltage imbalance and extends overall battery life.
**Idle Storage Management:** If the forklift is to be idle for an extended period (more than 15 days), fully charge the battery before storage. During storage, recharge the battery once a month to prevent self-discharge and sulfation of the plates. Store in a dry, well-ventilated environment, avoiding direct sunlight and humidity. Keep the battery away from fire and heat sources to prevent casing aging and deformation.