Hi, we have HELI (China) CPD20 type (capacity 2000kg) battery operated forklift. it is powered by a battery set of 24 lead acid cell (each of 2V) 48V D-620 type. we recently find a problem that had never occurred that its lead becomes very very hot and discharges quickly. it is supposed that there might be some short circuit in the components. would anybody like to give any solution?
Disconnect the batteries and measure each cell to see if you have a shorted battery.
And check the water - acids level the bad cell usually has almost no water because it boils out
electrolyte level is perfectly alright but specific gravity of almost all cells is i.210.
If it was given sufficient time to charge, then that reading showing your at 50% charge. Could be your battery is just worn out, how old are they
How far from the connector do the leads get hot and does the connector get hot? If it does check the condition of the terminals in the connector for a burned condition or oxidation, this can generate a tremendous amount of heat. What kind of terrain is the forklift operating, hard surface or soft? What are the tires inflated to, each 10% under the proper inflation will create a 20% increase in current draw. Are the brakes dragging or is there any foreign material wrapped around any of the wheel spindles. A low battery will create extra heat but with the modern electronics any low voltage condition will prevent the machine from operating to prevent damage. You can monitor the current draw with a clamp on ammeter and refer to Heli's specifications for reference.
Well, they are around 5 years or rather more but the forklift is not used daily. It is normally used once in a week for four to eight hours.