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 (scissor lift, articulating boom lift, telescopic boom lift) needs replacement, the key criteria are five aspects: appearance safety, working duration/range, charging performance, voltage/internal resistance, and service life. The battery should be replaced if there are safety hazards or severe performance degradation.

I. Appearance Inspection (Safety Red Line – Replace Immediately if Found)

Lead-acid Batteries

• Obvious bulging, deformation, cracking or leakage of the casing
• White/green powder (sulfuration/corrosion) on terminals/poles
• Pungent sour odor, turbid electrolyte, or heavy sediment at the bottom

Lithium Batteries

• Bulging, overheating, burnt smell or smoke from the battery pack
• Damaged casing, water ingress, or severe corrosion/burning of wiring terminals
• Constantly lit BMS fault light or frequent triggering of protection mechanisms

II. Working Duration / Range (Most Intuitive Judgment)

• Significantly shorter continuous working time after full charge (a drop of more than 40% compared with a new/normal battery)
• Rapid power loss, weak performance, or power drop under load during lifting, traveling or steering
• Sudden low-voltage alarm, automatic arm lowering or power-off protection during operation
• Industry Standards:
• Actual capacity ≤ 60%–70% of the rated capacity → recommended for replacement
• Actual capacity ≤ 50% of the rated capacity → must be replaced

III. Abnormal Charging (Typical Signs of Aging)

• Abnormal charging time:
• Severe overheating during charging: the battery/charger becomes scalding hot
• Obvious power loss (high self-discharge) after being left idle for half a day or one night

IV. Voltage and Internal Resistance (Professional Judgment)

Lead-acid (2V per cell, commonly 24V/48V)

• Standby voltage: per cell < 2.05V (24V battery pack < 24.6V, 48V battery pack < 49.2V)
• Rapid voltage drop and large fluctuations during discharge
• Significantly increased internal resistance (measured by a battery internal resistance tester)

Lithium Iron Phosphate (24V/48V)

• Low standby voltage after full charge, cell voltage difference > 0.1V
• Sharp voltage drop under load or frequent BMS protection triggering
• Internal resistance > 1.5–2 times the initial value

V. Service Life and Cycles (Reference Thresholds)

Lead-acid Batteries

• Regular use: 1–3 years, 300–500 cycles
• Rental/heavy-duty use: obvious degradation within 1–2 years

Lithium Iron Phosphate (LiFePO4)

• Design life: 4–6 years, 2000–3500 cycles
• Common 5-year manufacturer warranty
• Capacity testing is recommended after 5 years of use

VI. Quick Judgment Summary (Replace if Multiple Signs Occur)

• Bulging, leakage, corrosion, overheating or peculiar smell → replace immediately
• Halved working duration, power drop under load, or frequent low-voltage alarms → replace
• Extremely fast/failed charging or high self-discharge → replace
• Capacity < 60%, excessive internal resistance or abnormal voltage → replace
• Lead-acid battery over 3 years / lithium battery over 5 years with poor performance → recommended for replacement