When using an electric forklift, safety and operational efficiency are paramount. Below are key considerations organized by category to ensure safe and effective use:

1. Pre-Operation Checks

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 (avoid overfilling).

Ensure the battery is fully charged before starting a shift to avoid sudden power loss.

Brakes and Steering:

Test brake responsiveness and ensure steering moves smoothly without sticking or unusual noise.

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) to prevent unintended movement.

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 the center of gravity.

Avoid raising or lowering the load while driving, especially on uneven surfaces.

Load Placement:

Ensure the load is centered on the forks and securely positioned to prevent shifting.

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.

Reduce speed when turning to prevent tipping.

Surface Conditions:

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

Avoid sudden stops or accelerations on slippery surfaces.

Pedestrian Awareness:

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

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

Ramp Operation:

Drive up ramps in forward gear and down ramps in reverse to maintain control.

Never turn on a ramp.

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).

Never smoke or use open flames near charging batteries.

Handling Batteries:

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

If electrolyte leaks, neutralize with baking soda and water and clean up immediately.

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.

Accident Protocol:

Train operators on emergency stop procedures and how to safely exit the forklift if it tips over (e.g., stay seated, grip the steering wheel, and brace for impact).

Spill Response:

If electrolyte leaks from a lead-acid battery, contain the spill with absorbent material (e.g., sand or vermiculite) before cleaning.

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. 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.

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