Forklifts battery transfer

Electric Forklifts, Battery Charging and Changing Procedures

August 26, 2016
Posted by: admin

Electric forklifts are powered by large lead-acid batteries, which must be routinely charged.

Electric-powered forklifts are most commonly used indoors in warehouses. Unlike internal combustion forklifts, electric forklifts are quiet and generally non-polluting but present other serious hazards that must be addressed.

Electric forklifts produce zero emissions, virtually eliminate the hazard of carbon monoxide poisoning, and run more quietly than internal combustion forklifts. However, electric forklifts present other serious hazards that must be addressed.

Forklifts Battery Roller

Potencial Hazards:

Electric forklifts are powered by large lead-acid batteries, which must be routinely charged. The hazards and recommended practices for charging and changing batteries are reviewed below.

Requirements and Recommended Practices:

  • Designate an area for the purpose of battery charging.
  • Make sure that the forklift is charged before using.
  • Recognize that heavy loads drain the battery more quickly.

Battery Charging Area

A properly equipped battery charging area will have:

  • No smoking.
  • Warning signs posted.
  • Adequate fire protection.
  • Ample and readily available water supply for flushing and neutralizing spilled electrolyte.
  • An eyewash able to provide a 15 minute flow.
  • A phone or other means of communication in the event of an emergency.
  • Adequate ventilation to avoid the build up of hydrogen gas during battery charging.
  • Soda ash or other neutralization materials in the immediate area.
  • A dry chemical, CO2 or foam fire extinguisher.
  • Means to protect charging apparatus from damage from trucks.

Battery Charging and Changing Procedures

An electric forklift is designed to operate for one shift and then be charged on the next shift or overnight. Some employers routinely change batteries instead of charging them in the vehicle. The discharged battery is removed from the forklift and a charged battery is installed in its place.

Only trained personnel should charge and change batteries in electric forklifts. In addition to training in battery changing and charging procedures, these employees should be trained on emergency procedures in the event of an acid splash, including how to use eyewash and shower facilities.

Potential Hazards:

  • Batteries are very heavy.
  • Batteries contain sulfuric acid that is highly corrosive and could be splashed on personnel servicing or changing batteries.
  • Toward the end of the battery charging process, batteries can give off highly explosive hydrogen fumes.
  • Contact with battery cells can cause electrical short circuits, which can burn unprotected skin.

Requirements and Recommended Practices:

  • Always follow your facility’s specific safety procedures. Follow the recharger manufacturer’s recommendations for attaching and removing cables and for proper operation of your equipment.
  • Properly position trucks and apply brakes before attempting to change or charge batteries.
  • Use a lifting beam or equivalent material handling equipment when lifting the battery. Do not use a chain with two hooks. This may cause distortion and internal damage.
  • Charge batteries in the designated battery charging area.
  • Facilities shall be provided for flushing and neutralizing spilled electrolyte, for fire protection, for protecting charging apparatus from damage by trucks, and for adequate ventilation for dispersal of fumes from gassing batteries.
  • When charging batteries, pour acid into water. Never pour water into acid.
  • Care shall be taken to assure that vent caps are functioning. The battery (or compartment) cover(s) shall be open to dissipate heat.
  • Prohibit smoking in the charging area.
  • Take precautions to prevent open flames, sparks, or electric arcs in battery charging areas.
  • Remove all metallic jewelry before recharging. Tools and other metallic objects shall be kept away from the top of uncovered batteries.
  • Wear personal protective equipment (face shield, safety goggles, neoprene or rubber gloves and apron).
  • Where the eyes or body of any person may be exposed to injurious corrosive materials, suitable facilities for quick drenching or flushing of the eyes and body must be provided within the work area for immediate emergency use.
  • Check the electrolyte level before recharging. Record the specific gravity with the hydrometer in the service log. Check the pilot cell.
  • Check the water level. Do not add water prior to recharging. Record in service log.
  • Check the voltage. If the battery has sealed vents, do not recharge with a current greater than 25 amperes.
  • Unplug and turn off the charger before connecting or disconnecting the clamp connections.
  • Turn off the charger if the battery becomes hot or the electrolyte fluid comes out of the vents. Restart charging at a lower charging rate.
    Check water level after charging. Add distilled water or de-ionized water if water level is below level indicator. Record in service log.
  •  Return battery to forklift with lifting beam and secure in place after charging.
  • Check the indicator on the hour meter to see that battery is fully charged.

Battery Maintenance

Under normal operating conditions, power industrial truck forklift batteries can be expected to remain in service for 2,000 work shifts or charge/discharge cycles. Implementing a proper battery maintenance program can increase the life of the batteries and help protect employees. Battery failure could lead to mechanical breakdowns and possible accidents involving forklift operators and/or other personnel.

  • Do not continue a battery in service merely because it continues to deliver power.
  • Do not exceed the service hours in the manufacturer’s recommendations.
  • Do not over charge or under charge batteries.
  • Avoid discharging batteries beyond the manufacturer’s discharge level. This can result in permanent battery damage and shorten battery life considerably.
  • Warning signs of a low battery include slow starting, dim headlights, and the ammeter indicating discharge at high RPM.
  • Recycle or properly dispose of batteries.
  • Spent batteries are a hazardous waste unless they are properly reclaimed at a lead smelter or battery recycler.

When charging batteries, pour acid into water. Never pour water into acid.

1 Comment

  • My brother has been having trouble when it comes to his forklifts batteries, probably because it’s not being charged on a regular basis. It’s a great thing that you’ve mentioned the importance of pouring acid into the water and not vice versa. We’ll try to fix this, but I guess it’s better if I’ll look for a forklift repair service that can do this procedure properly.

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