Precautions for Electric Forklifts at Different Stages of Use

Electric forklifts require careful handling throughout their lifecycle—from initial operation to long-term maintenance—to ensure safety, efficiency, and longevity. Below are key precautions for each stage of use:

1. Pre-Operation (Before Starting Work)

Key Checks & Precautions:

Battery Inspection

Check electrolyte levels (for lead-acid batteries) and ensure terminals are clean and tight.

Verify charging status (avoid using if battery is critically low).

Ensure proper ventilation in the battery compartment to prevent gas buildup.

Brake & Steering Tests

Test brakes for responsiveness (parking brake should hold firmly).

Check steering smoothness (no excessive play or stiffness).

Hydraulic System Check

Inspect for oil leaks (especially around cylinders and hoses).

Test lift/lower functions to ensure smooth operation.

Tire & Wheel Inspection

Check tire pressure and tread depth (replace if worn or damaged).

Ensure wheels are securely fastened (no loose nuts/bolts).

Safety Devices Verification

Test horn, lights, and alarms (must be audible/visible from all directions).

Ensure seatbelt and operator presence sensor (OPS) are functional.

Environmental Assessment

Check for obstacles, uneven surfaces, or wet/oily floors.

Ensure adequate lighting in the working area.

2. During Operation (While Using the Forklift)

Key Safety Practices:

Load Handling Precautions

Never exceed rated load capacity (check data plate).

Ensure load is stable, centered, and secured before moving.

Avoid sudden stops/starts or sharp turns with a raised load.

Driving & Maneuvering Rules

Drive at a safe speed (adjust based on load and environment).

Keep a clear view ahead; use a spotter if visibility is obstructed.

Maintain a safe distance from pedestrians, racks, and other vehicles.

Battery & Electrical Safety

Avoid exposing the forklift to water/rain (risk of short circuits).

Do not touch battery terminals with bare hands (risk of electric shock).

If smoking/sparking occurs, stop use immediately and inspect for faults.

Emergency Procedures

Know the location of emergency stops and fire extinguishers.

If the forklift tips over, stay seated, grip the steering wheel, and brace yourself.

Avoiding Common Mistakes

Do not use the forklift as a personnel lift (use designated platforms).

Never drive on slopes with a raised load (lower forks first).

Avoid blocking exits or aisles during operation.

3. Post-Operation (After Use & Maintenance)

Critical Steps for Longevity & Safety:

Proper Shutdown & Storage

Lower forks completely and set parking brake before exiting.

Turn off lights, horn, and all controls before leaving the vehicle.

Store in a dry, well-ventilated area (away from flammable materials).

Battery Maintenance

Charge the battery only after cooling down (avoid charging immediately after use).

Use the correct charger (matching voltage/current specifications).

For lead-acid batteries, check water levels after charging (add distilled water if needed).

Cleaning & Inspection

Remove dirt/debris from the forklift (especially hydraulic components).

Inspect for damage (cracks, leaks, worn parts) and report issues promptly.

Lubricate moving parts (chains, bearings, steering components) as needed.

Long-Term Storage Precautions

If storing for extended periods, fully charge the battery and disconnect it.

Store in a climate-controlled environment (prevent battery degradation).

Periodically start the forklift (if possible) to prevent mechanical seizure.

4. Periodic Maintenance & Inspections

Scheduled Checks for Optimal Performance:

Daily Inspections

Battery fluid levels & terminal condition.

Brake, steering, and hydraulic system functionality.

Tire pressure and general cleanliness.

Weekly/Monthly Checks

Lubricate chains, bearings, and pivot points.

Test emergency stop and safety systems.

Inspect electrical wiring for damage/corrosion.

Annual/Major Inspections

Professional inspection of hydraulic system (seals, hoses, cylinders).

Thorough battery test (capacity, cell balance).

Structural integrity check (frame, mast, forks).

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