When using an electric forklift, prioritizing safety is critical to preventing accidents, equipment damage, and operational disruptions. Below is a structured guide outlining key precautions to follow during operation, maintenance, and storage:

1. Pre-Operation Safety Checks

Before starting the forklift, conduct a daily inspection to ensure safe operation:

Battery Inspection:

Check for corrosion on terminals, loose connections, or leaks (especially for lead-acid batteries).

Verify electrolyte levels (if applicable) and top up with distilled water only.

Brakes and Steering:

Test brake responsiveness and ensure steering moves smoothly without sticking.

Tires:

Inspect for cuts, punctures, or low pressure (pneumatic tires) or excessive wear (cushion tires).

Hydraulic System:

Check for leaks around hoses, cylinders, and the mast. Test lift/lower functions for jerky movements.

Safety Features:

Ensure lights, horns, alarms, and mirrors are functional.

Test the seatbelt and operator presence sensor (if equipped).

Fork Condition:

Look for cracks, bends, or uneven wear on forks and load backrest.

Action: If any issues are found, tag the forklift as “Out of Service” and report it to a supervisor immediately.

2. Safe Operating Practices

A. Load Handling

Capacity Limits:

Never exceed the forklift’s rated load capacity (check the data plate). Overloading can cause tip-overs.

Load Stability:

Keep the load low and tilted back when moving to maintain center of gravity.

Avoid raising or lowering the load while driving.

Visibility:

Drive in reverse if the load obstructs forward visibility (e.g., when carrying tall items).

Use a spotter if needed for blind spots.

B. Driving Safety

Speed Control:

Drive at a safe, controlled speed, especially on ramps, wet floors, or uneven surfaces.

Turning:

Slow down before turns to prevent tipping. Avoid sharp turns with a raised load.

Surface Conditions:

Watch for oil spills, debris, or potholes that could cause skidding or loss of control.

Pedestrian Awareness:

Sound the horn at intersections, doorways, and blind corners.

Maintain a 3-meter (10-foot) distance from pedestrians when possible.

C. Battery Safety

Charging Precautions:

Charge batteries in a well-ventilated area to prevent hydrogen gas buildup (explosive hazard).

Use manufacturer-approved chargers and avoid overcharging (stop at 100% or as recommended).

Handling Batteries:

Wear acid-resistant gloves, goggles, and apron when handling lead-acid batteries.

Never smoke or use open flames near batteries.

3. Environmental Precautions

Workplace Hazards:

Avoid operating near open flames, sparks, or flammable materials (electric forklifts are safer than IC models but still pose risks).

Temperature Control:

Store and operate forklifts in moderate temperatures (avoid extreme cold or heat, which can affect battery performance).

Cleanliness:

Keep the forklift clean of grease, oil, or debris to prevent slips and falls.

4. Emergency Procedures

Fire Safety:

Keep a Class D fire extinguisher (for metal fires) or CO2 extinguisher nearby when charging batteries.

Spill Response:

If electrolyte leaks from a lead-acid battery, neutralize with baking soda and water and clean up immediately.

Accident Protocol:

Train operators on emergency stop procedures and how to safely exit the forklift if it tips over.

5. Maintenance-Related Precautions

Lockout/Tagout (LOTO):

Disconnect the battery and isolate energy sources before performing maintenance or repairs to prevent accidental startup.

PPE (Personal Protective Equipment):

Wear safety glasses, gloves, and steel-toe boots during inspections or repairs.

Component Inspection:

Regularly check brakes, hydraulic hoses, and electrical wiring for wear or damage.

6. Operator Training and Certification

Formal Training:

Ensure operators complete OSHA-compliant training (or equivalent) covering controls, load handling, and safety protocols.

Refresher Courses:

Schedule annual or as-needed training to address new hazards or operational changes.

7. Storage Precautions

Short-Term Storage:

Park the forklift on a level surface with the forks lowered and the parking brake engaged.

Turn off the key and remove it to prevent unauthorized use.

Long-Term Storage:

Charge the battery to 50–70% capacity to prevent sulfation (for lead-acid batteries).

Store in a dry, cool place away from direct sunlight or moisture.

Common Hazards to Avoid

Hazard Prevention Measure

Tip-overs Keep loads low, drive slowly, and avoid sharp turns.

Battery explosions Charge in a ventilated area and avoid sparks.

Crushing injuries Never walk under raised forks or allow riders.

Electrocution Inspect wiring regularly and avoid wet conditions.

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