How to handle abnormal heating of the battery in a 2-ton electric forklift?

Handling of Abnormal Heating of the Battery in a 2-Ton Electric Forklift

The core approach to addressing abnormal heating of the battery in a 2-ton electric forklift consists of immediate damage control, safety inspection, and professional intervention. This is to prevent aggravated heating from triggering hazards such as fire and explosion. Follow the steps below for handling:

I. Emergency Response (Must be performed immediately)

1. Immediately stop charging or operation, turn off the forklift's power supply, pull out the key, disconnect the main battery switch, and cut off the current circuit.
2. Move the forklift to a well-ventilated and open area (away from flammable materials and crowded places). If the forklift cannot be moved, open the surrounding doors and windows to enforce ventilation.
3. Observe the heating intensity:
• If only slightly warm (can be touched by hand for more than 10 seconds), let it stand for 30 - 60 minutes to cool down.
• If extremely hot (too hot to touch), accompanied by swelling, smoke, or unusual odors, evacuate the scene immediately and call the manufacturer or maintenance personnel for further instructions.

II. Safety Inspection (Simple self-inspection allowed after cooling down)

1. Inspect the battery terminals when the power is off. If oxidation or looseness is found, wipe the surface with a dry cloth. For severe oxidation, lightly polish with sandpaper and re-tighten the connections (do not operate with power on).
2. Verify the charger model to ensure it matches the battery (e.g., a 48V battery should be paired with a 48V charger). If mismatched, stop using the charger immediately.
3. For lead-acid batteries, check the electrolyte level. If it is below the scale line, add distilled water (do not add electrolyte or tap water) to prevent insufficient level from worsening heating.
4. Inspect whether the battery case is damaged or if electrolyte is leaking. In case of leakage, treat the spilled substance with dry sand or absorbent cotton, and never touch it directly with hands.

III. Prohibited Operations (To avoid secondary hazards)

1. Do not pour water or spray coolant on the overheating battery. Contact with water may cause the battery to short-circuit, leading to electric shock or explosion.
2. Do not continue charging, start the forklift, or disassemble the internal structure of the battery. Unprofessional disassembly is likely to cause electrolyte splashing, short-circuit, and fire.
3. Do not smoke or use open flames near the overheating battery. The battery may release flammable gases when heated, which can easily ignite when exposed to fire.

IV. Follow-up Handling and Prevention

1. If abnormal heating persists after inspection (e.g., reheating after standing or unrelieved swelling), contact professional maintenance personnel to test the battery's internal resistance and plate condition. Batteries that are aged or have internal short-circuits must be replaced promptly.
2. Replace the faulty charger (if confirmed damaged). Prioritize using original or qualified products of the same specification.
3. Subsequently, strictly adhere to the principle of "charging as needed and avoiding overcharging and overdischarging". Regularly clean the battery terminals to prevent the recurrence of similar problems.