Forklift battery will inevitably experience degradation in battery performance with increased usage time, where certain battery cells may become damaged or lose capacity.
At this point, instead of replacing the entire battery pack, it is economical and environmentally friendly to choose to replace only the faulty battery monobloc. However, how to correctly remove the battery monobloc from the forklift battery during operation is a highly technical issue.
一．Preparations: ensuring security
Before disassembling the forklift battery monobloc, the safety norms must be strictly observed:
Disconnect operation: First ensure that the forklift truck is in the off state and completely disconnect the power supply connection with the battery to prevent arcing or short-circuiting during the disassembly process.
Wear protective equipment: Operators must wear insulated gloves, acid-proof goggles and overalls to avoid injury caused by electrolyte leakage.
二．Tools
Commonly used tools include insulated wrenches, battery lifting harnesses, voltage detectors, welding tools, carbon rods, electric drills, 30mm drill bits, connection plates, etc. It is strictly prohibited to use metal tools with bare hands to avoid short circuits.
三．Detection of faulty battery cells
Measurement of voltage: Use a voltmeter to measure the terminal voltage of each cell one by one, significantly lower than the normal voltage (e.g., lower than 1.75V for a 2V cell) usually indicates abnormal performance.
Detect internal resistance: Elevated internal resistance may also indicate battery aging or plate sulfation.
四．How to properly disassemble the battery monobloc
1, find out the corresponding need to replace the monobloc, with an electric drill to connect the board after drilling out, remove the battery monobloc. The board is arranged, keep seamless with the battery monobloc, and then make sure that the flow of welding lead can be wet napkins, wrapped around its edges and seams.
2, welding. Take the voltage between 6-10V, put the carbon rod after burning red into the welding rod flow full, make sure that the battery poles and connecting plate welded firmly.
3、Check whether the connection plate is firmly welded, you can use tools to pry the connection plate, grinding to ensure that the surface is smooth and flat.
Precautions for Replacing New Battery Monoblocs
The new battery must be consistent with the original battery model, voltage and capacity to avoid performance mismatch;
The installation direction should be correct, and the polarity should not be reversed;
All connection bolts must be tightened to avoid poor contact;
Re-measure the overall voltage after installation and perform preliminary charging to ensure balanced operation of the battery pack.
After replacing a single battery, the whole battery pack should be equalized and charged once to prevent early loss due to capacity difference between the old and new batteries.
It is also recommended to regularly check the battery voltage, electrolyte specific gravity and appearance status every month to detect potential failures in time.