Comprehensive Guide to Precautions for the Use of Electric Forklifts

1、 Battery maintenance and management

1. Charging standards

Specialized charger: It is necessary to use a specialized charger that matches the battery model to avoid overcharging or undercharging.

Lead acid batteries: follow the principle of "using the car every day, charging it every day" to prevent power loss (charging immediately when there is 20% remaining power).

Lithium batteries: Avoid storage in high temperature (>45 ℃) or low temperature (<-10 ℃) environments, and recharge them once a month when they are not in use for a long time.

Charging environment: The charging area should be well ventilated, equipped with dry powder fire extinguishers, and kept away from open flames.

2. Electrolyte inspection

Liquid level monitoring: Regularly check the electrolyte level (lead-acid battery). When the liquid level is below the indication of the injection valve, add distilled water or deionized water. It is forbidden to add tap water.

Recharge frequency: Perform balanced charging every 500 working hours (approximately 3-4 months) and replenish water.

3. Surface cleaning

Daily cleaning: Use a damp towel to wipe the surface of the battery to avoid static electricity or short circuits; Remove corrosive substances from the wiring terminals and apply Vaseline to prevent oxidation.

Dirt treatment: Clean the surface stains of the battery in a timely manner to prevent an increase in self consumption.

4. Deep discharge and activation

Quarterly operation: Conduct a deep discharge once every quarter (until under voltage protection) to activate the active material of the electrode plate and increase the battery capacity.

Avoid excessive discharge: Do not discharge the battery below 40% to avoid irreversible damage.

5. Long term storage management

Discontinuation treatment: When the battery is not in use for a long time, it should be fully charged and stored. It should be recharged once a month to prevent sulfurization.

Environmental requirements: Store in a cool, dry, ventilated place, away from direct sunlight.

2、 Safety operation standards

1. Check before startup

Battery and Instrument: Confirm that the battery is fully charged and the instrument has no fault alarms.

Mechanical components: Check the sensitivity of the brake and steering systems, ensure that the forks are not deformed, and that the tire pressure is normal (6-8 bar for the front wheels and 4-6 bar for the rear wheels).

Environmental confirmation: Check for no personnel or obstacles within 1.5 meters of the vehicle and sound the horn for warning.

2. Driving rules

Speed limit requirements:

Within the factory area: straight-line driving ≤ 5km/h, complex areas (turns, narrow passages) ≤ 3km/h.

Warehouse doors, ramps, and other areas: speed ≤ 10km/h.

Fork height: When driving, the fork should be 30-40cm above the ground, and when carrying cargo, it should not exceed the line of sight height.

Prohibited behaviors: sharp turns, slope turns, carrying people or lifting personnel with forks.

3. Loading and unloading requirements

Fixed goods: The center of gravity of the goods is centered, the width does not exceed the fork, and the height does not exceed the shelf.

Operation process:

After inserting the tray, lift it 5-10cm before moving it. It is strictly prohibited to drive while lifting.

When unloading, ensure that the unloading point is stable and the forks are completely removed before driving.

Special cargo: When large cargo blocks the line of sight, reverse the vehicle and be directed by a designated person.

4. Emergency response

Fault handling: In case of sudden malfunction, immediately power off, place warning signs, and contact maintenance personnel.

Leakage treatment: Do not touch the vehicle body, cut off the main power supply and use insulated tools for treatment.

Accident report: After an accident occurs, protect the scene and immediately report to the supervisor.

5. Parking requirements

Parking position: Park in the designated area, with the forks fully landing in a horizontal position.

Power management: Turn off the power and remove the key, and open the battery compartment cover to dissipate heat while charging.

Adverse weather: In rainy and snowy weather, park in the rain shelter and clean up the accumulated water and ice on the forks.

3、 Daily inspection and maintenance

1. Daily check

Battery system: Check the electrolyte level (lead-acid battery) or battery status (lithium battery), clean the surface acid or dust.

Electrical system: Test the functions of turn signals, headlights, and reverse buzzer.

Mechanical components: Check the lubrication and tension of the fork chain, tire pressure and tread condition.

Hydraulic system: Check the oil level and color, test the functions of the hydraulic pump and distribution valve.

2. Weekly maintenance

Battery cleaning: Clean the surface and terminals of the battery, apply Vaseline to prevent oxidation.

Braking system: Check the thickness of brake pads, brake fluid level, and test steering sensitivity.

Lubrication task: lubricate the guide rails, bearings, and chains of the gantry.

3. Monthly maintenance

Hydraulic system: Check the hydraulic oil level and cleanliness, and replace it if necessary (recommended every 500 hours).

Motor inspection: Check the wear of the motor carbon brush and clean the dust at the motor cooling port.

Bolt tightening: Tighten all bolts of the vehicle, with a focus on checking the fixing bolts of the wheel hub and fork.

4. Quarterly maintenance

Electrical circuit: Test the insulation of electrical circuits and investigate the oxidation of controller and contactor contacts.

Steering and Braking: Calibrate the steering system angle and braking force, and check the condition of the gearbox gear oil.

Cooling system: Clean the cooling fan and ventilation duct to prevent overheating.

5. Annual maintenance

Professional testing: Entrust professional personnel to test the motor performance and electrical control system parameters.

Component replacement: Replace the hydraulic oil filter and air filter, and check the sealing of the hydraulic pump.

Load testing: Conduct a vehicle load test to verify the load-bearing stability of the gantry.

4、 Operator training and management

1. Qualification requirements

Certified on duty: Operators must undergo professional training and obtain a special equipment operation certificate.

Regular refresher training: Receive safety operation and emergency response refresher training every year to update operational skills.

2. Battery maintenance training

Charging operation: Train on the correct charging process, electrolyte replenishment method, and fault identification.

Safety awareness: Emphasize the prohibition of overcharging, undercharging, mixed use of chargers and other violations.

3. Safety operation standards

Speed limit compliance: Strictly follow the speed limit regulations in the factory area, avoid sudden acceleration and braking.

Cargo management: Overloading is prohibited, ensuring that the cargo is securely fixed and avoiding tilting or slipping.

5、 Environmental adaptation and storage

1. Work environment requirements

Ground cleaning: Keep the work area floor free of debris (such as wooden pallets, oil stains) and avoid entangling tires.

Wet environment: Wipe the vehicle body dry promptly after homework to prevent electrical components from short circuiting.

2. Storage management

Parking location: Park on a flat surface, with the fork on the ground, turn off the power and remove the key.

Long term storage: The battery needs to be fully charged, recharged once a month, and stored in a cool and ventilated place.

6、 Compliance and Standards

1. Follow the standards

International standards: Follow OSHA (Occupational Safety and Health Administration) standards to perform safe operations.

Domestic standards: comply with national standards such as GB/T 27542-2011 "Safety Requirements and Verification for Industrial Vehicles".

2. Record management

Maintain archives: Establish detailed maintenance records, including inspection dates, maintenance content, replacement parts, and operator signatures.

Fault tracing: By recording and analyzing the causes of faults, optimize maintenance plans.

7、 Special scenario precautions

1. Low temperature environment (below -10 ℃)

Battery performance: The capacity of lead-acid batteries has decreased to 70% -75%, and it is necessary to fully charge them in advance and shorten the operation interval.

Operation adjustment: Reduce sudden acceleration, avoid high current discharge, and assist with manual starting if necessary.

2. High temperature environment (>35 ℃)

Battery cooling: Ensure good ventilation during charging and avoid direct sunlight in the battery compartment.

Hydraulic system: Check the viscosity of hydraulic oil and replace it with high-temperature suitable oil if necessary.

3. Multi shift handover

Information recording: Record the remaining battery level, fault codes, and abnormal situations during handover.

Quick inspection: The incoming personnel need to perform daily safety checks to confirm the equipment status.

The main equipment produced by Hebei Makita: stage electric hoist, electric chian hoist, wire rope electric hoist，Hand chain hoist, lever hoist, pneumatic hoist and other lifting equipment