How to Determine if the Battery of an Electric Aerial Work Platform Needs Replacement

To determine whether the battery of an electric aerial work platform (elevating work platform) needs replacement, the core criteria are 5 major warning signs + professional testing + service life. Replacement is generally necessary if there is a sudden drop in endurance, abnormal charging, bulging or leakage of the battery, unstable voltage, or severe overheating.

I. Visual & Physical Inspection (Most Intuitive)

• Bulging / DeformationObvious expansion or protrusion of the battery casing indicates internal gas generation and structural damage, which is a dangerous warning — the battery must be replaced immediately.
• Leakage / CorrosionWhite/green powder (sulfation) on terminals, fluid seepage from the casing, or a pungent odor indicates battery failure and corrosion risks.
• Cracks / DamageCracking or breakage of the casing means internal damage — replace immediately.

II. Operating Performance Judgment (Most Commonly Used)

• Significant Reduction in Endurance / Working Hours
• Abnormal Charging
• Weak Power / Unstable Voltage
• Severe Self-DischargeFully charged battery loses power / fails to start after being idle for 3~7 days → internal leakage and aging.

III. Professional Instrument Testing (Most Accurate)

1. Voltage Measurement (Multimeter)

• Standing Voltage (1 hour after full charge):
• Load Voltage (during traveling / lifting):Instant voltage drop ＞3~5V → insufficient capacity and high internal resistance.

2. Capacity Testing (Capacity Tester)

• Standard: replace when actual capacity ＜ 80% of rated capacity.Example: 240Ah battery → replacement recommended if measured ＜ 192Ah.

3. Internal Resistance Testing (Internal Resistance Meter)

• Internal resistance 30%~50% higher than a new battery → performance degradation.
• Lead-acid: single cell internal resistance ＞5mΩ; lithium-ion: internal resistance exceeding manufacturer’s threshold → aging.

IV. Service Life Reference (Empirical Values)

• Lead-acid batteries (FLA/AGM): 3~5 years, 1000~1500 cycles.
• Lithium Iron Phosphate (LFP) batteries: 4~6 years, 2000~3000 cycles.Replace directly if exceeding service life and performance declines.

V. Summary of Replacement Criteria (Replace if Any 2 Conditions Are Met)

1. Appearance: bulging, leakage, damage.
2. Endurance: working hours reduced by 40%+.
3. Charging: fast false charge / incomplete charge / overheating.
4. Performance: sharp voltage drop under load, weak power, constant fault light.
5. Testing: capacity ＜80%, excessive internal resistance.
6. Service life: lead-acid over 5 years / lithium-ion over 6 years.

VI. Safety Reminders

• If bulging, leakage, severe overheating, or odd odors occur → stop use immediately, prohibit charging, and arrange professional replacement.
• Replace with a complete set of the same brand and model; mixing old and new batteries will accelerate damage to new batteries.