How To Change EP25-35CN Forklift Battery?
Replacing an EP25-35CN forklift battery requires strict adherence to safety protocols due to its weight (600–900 kg) and high voltage (48V–80V). Key steps include: de-energizing the forklift, using certified lifting gear, disconnecting terminals in reverse order (negative first), and installing the new battery with proper alignment. Always consult the OEM manual for torque specs and disposal guidelines. Lithium-ion variants demand additional BMS compatibility checks.
48V 550Ah LiFePO4 Forklift Battery Pack
What tools are needed for EP25-35CN battery replacement?
Essential tools include insulated wrenches, overhead crane/chain hoist, and battery sled alignment guides. PPE like voltage-rated gloves and steel-toe boots are mandatory. Hydraulic jacks may stabilize the forklift during extraction.
EP25-35CN batteries weigh up to 900 kg, requiring 2,000 lb-rated lifting straps and load-balanced spreader bars. Pro Tip: Use laser alignment tools to verify terminal positioning—even 3 mm misalignment strains connectors. For example, Toyota 8FGU25 forklifts require 120 N·m torque on terminal bolts. Undertorquing risks arcing, while overtightening strips threads. Always replace corroded terminals with OEM parts. But how do you avoid damaging fragile BMS wiring? Route cables away from pinch points and secure them with nylon ties.
| Tool | Spec | Purpose |
|---|---|---|
| Insulated Wrench | 18–24 mm | Terminal removal |
| Chain Hoist | 1–2 ton capacity | Battery lifting |
| Torque Wrench | 50–150 N·m | Bolt fastening |
What safety steps precede battery removal?
Critical steps: disable forklift ignition, ventilate hydrogen gas, and verify lockout/tagout (LOTO). Test battery voltage with a multimeter to confirm discharge below 50V for lead-acid or 10% SOC for lithium.
Forklifts generate hydrogen during charging—sparks from disconnecting terminals can cause explosions. Pro Tip: Use gas detectors to ensure H₂ levels stay under 2% LEL. Neutralize electrolyte spills with baking soda. Lithium batteries require discharging to 10–15% SOC to minimize fire risks. What if the battery compartment is corroded? Scrub terminals with brass brushes and apply anti-corrosion gel post-installation. Transitionally, after powering down, disconnect auxiliary systems like dash displays to prevent voltage spikes.
How to remove the old EP25-35CN battery?
Extraction involves unbolting restraints, lifting vertically, and transferring to a storage pallet. Tilt the forklift mast back 10°–15° to avoid tipping during extraction.
Loosen four corner restraint bolts (typically M12–M16) using impact wrenches set to 80–100 N·m. Pro Tip: Mark battery orientation with paint pens—reverse installation damages polarity-sensitive controllers. For flooded lead-acid models, inspect trays for acid damage; replace warped trays to prevent misalignment. But why avoid tilting batteries beyond 30°? Excessive angles cause electrolyte leakage in lead-acid or internal short circuits in lithium-ion. Use a battery sled with rollers for smooth horizontal extraction.
Battery Expert Insight
FAQs
Yes, but ensure the lithium BMS supports CANbus/J1939 protocols used in EP25-35CN forklifts. Retrofitting requires updating charger profiles to CC-CV with 80%–100% SOC limits.
How often should EP25-35CN batteries be replaced?
Lead-acid lasts 1,200–1,500 cycles; lithium variants reach 3,000–5,000 cycles. Replace when capacity drops below 60%—measured via discharge testing.