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1. Introduction

In the modern logistics and warehousing industry, forklifts, as indispensable handling equipment, are mostly powered by lead-acid batteries. Lead-acid batteries have the advantages of relatively low cost, mature technology and good high-current discharge performance, which can meet the needs of frequent starts and stops and heavy-load operations of forklifts. However, if not used properly, lead-acid batteries will not only affect the normal operation of forklifts, but also may cause a series of safety problems, such as fire, explosion, electrolyte leakage and corrosion, as well as personnel poisoning. Therefore, a thorough understanding and strict adherence to the safety precautions for the use of lead-acid batteries in forklifts are of vital significance for ensuring operational safety, extending the battery's service life, and enhancing work efficiency.

2. Preparations and Checks Before Use

(1) Selection and Installation of Storage Batteries

It is of vital importance to choose the right specification of lead-acid batteries. The battery with matching capacity and voltage should be selected based on parameters such as the model, rated power and working intensity of the forklift. If the capacity is too small, it may lead to insufficient endurance of the forklift and fail to meet the work requirements. If the capacity is too large, it will increase costs and may affect the stability of the forklift due to insufficient installation space.

2. During the installation process, it is essential to ensure that the installation position is firm and stable to prevent damage to the battery casing or loosening of the connections due to vibration. At the same time, it is necessary to ensure that the positive and negative terminals of the battery are connected correctly. Reverse connection is strictly prohibited. Reversing the connection not only damages the electrical system of the forklift but may also cause a short circuit, generate sparks, and subsequently lead to fire or explosion. In addition, insulating tools should be used during installation to prevent electric shock to the operators.

(2) Inspection of appearance and components

Before use, carefully check whether the battery casing is damaged, cracked or deformed. Even tiny cracks can lead to electrolyte leakage, corroding forklift components and the ground, and at the same time cause electrolyte loss, affecting the performance of the battery. Once the shell is found to be damaged, its use should be stopped immediately and a professional should be contacted for replacement.

2. Check whether the terminal posts are corroded or loose. Corrosion of the terminal post will increase the contact resistance, leading to a decrease in charging and discharging efficiency. In severe cases, it may even cause poor contact, resulting in the interruption of forklift power. If corrosion of the terminal post is found, it can be gently sanded with sandpaper and then coated with special anti-corrosion grease. If the terminal post is loose, it should be tightened with an appropriate tool, but be careful not to damage the terminal post by excessive force.

3. Checking the electrolyte level is also an important step. Under normal circumstances, the electrolyte level should be between the upper and lower limit marks marked on the battery case. If the liquid level is too low, the plates will be exposed to the air, causing sulfation of the plates and shortening the battery life. If the liquid level is too high, corrosion and contamination may occur during the charging process due to the overflow of the electrolyte. When the electrolyte level is too low, distilled water or special lead-acid battery replenishment liquid should be added. It is strictly forbidden to add tap water, as impurities in tap water may affect the performance of the battery.

(3) Electrical Connection and System Testing

1. Check whether the connection lines between the battery and the forklift's electrical system are intact, and whether there is any damage, aging or exposure. The insulation performance of aging circuits declines, making them prone to short circuits and posing a significant safety hazard. For damaged or exposed circuits, they should be replaced or repaired in a timely manner and proper insulation treatment should be carried out.

After the installation and wiring inspection are completed, the electrical system of the forklift should be tested. Turn on the power of the forklift, check whether the display on the instrument panel is normal, whether all indicator lights are on, whether the motor starts smoothly, and whether there are any abnormal noises or odors. If any abnormal situation is found, the use should be stopped immediately and inspected and repaired by a professional electrician to ensure that the electrical system is operating normally before it can be put back into use.

3. Safe Operation during Use

(1) Correct charging operation

1.The choice of a charging location is of vital importance. A dedicated charging area with good ventilation, dryness and far away from flammable and explosive items should be selected. During the charging process of lead-acid batteries, hydrogen and oxygen are produced. Hydrogen is a flammable and explosive gas. If it accumulates to a certain concentration in a closed space and encounters a fire source, it will cause an explosion. Therefore, the charging area must be equipped with good ventilation facilities to ensure that the gas can be discharged in time. At the same time, clear warning signs should be set up in the charging area. Smoking and the use of open flames are strictly prohibited.

2. Use the matching charger. Lead-acid batteries of different specifications require chargers of corresponding specifications. It is strictly prohibited to use incompatible chargers, otherwise it may lead to unstable charging voltage and current, damage the battery, and even cause a fire. Before connecting the charger, the power supply of the forklift should be turned off first, and then the positive and negative terminals of the battery should be correctly connected according to the instructions of the charger. During the charging process, strictly follow the set parameters of the charger and do not change the charging time or current size at will.

3. Monitoring during the charging process cannot be ignored. During the charging process, the temperature, voltage and electrolyte level of the battery should be checked regularly. Under normal circumstances, the temperature of a battery during charging should not exceed 45℃. If the temperature is too high, it may be due to excessive charging current or an internal fault in the battery. Charging should be stopped immediately, and a check should be conducted after the temperature drops. At the same time, observe the changes in voltage to ensure that the charging voltage is within the specified range. In addition, as the electrolyte undergoes an electrolytic reaction during the charging process, the moisture content will gradually decrease. Therefore, it is necessary to check the electrolyte level in a timely manner and replenish it as needed.

After being fully charged, the connection between the charger and the battery should be disconnected first, and then the power of the charger should be turned off. Avoid directly turning off the charger power when it is connected, as this may cause a momentary high voltage, damaging the charger and battery. After the charging is completed, do not use the forklift immediately. Let the battery stand for a period of time to allow the electrolyte to mix thoroughly, which will improve the performance of the battery.

(2) Reasonable discharge operation

Avoiding excessive discharge is the key to extending the lifespan of lead-acid batteries. Excessive discharge of lead-acid batteries can lead to sulfation of the plates, reducing the battery's capacity and service life. Generally speaking, when the forklift dashboard shows that the battery level remains at around 20% to 30%, it should be charged in a timely manner. In actual operation, the operator should reasonably arrange the charging time based on the working intensity of the forklift and the battery usage condition to avoid damaging the battery due to excessive discharge.

2. During the operation of the forklift, it should be operated smoothly to avoid sudden acceleration, sudden braking and frequent starts and stops. Sudden acceleration and sudden braking will cause the battery to discharge a large current instantaneously, increasing the burden on the battery and affecting its service life. Frequent starts and stops can also cause the battery to charge and discharge repeatedly, accelerating the aging of the battery. Therefore, operators should develop good driving habits, maintain a constant speed and operate the forklift smoothly.

3. Overloading operation is strictly prohibited. Overloading a forklift will increase the load on the motor, causing excessive output current from the battery. This not only affects the forklift's driving performance and safety but also causes irreversible damage to the battery. Before the operation, the operator should understand the rated load capacity of the forklift and load it strictly in accordance with the regulations to ensure that the forklift and the battery operate within the normal working load range.

(3) Daily Maintenance and upkeep

1. Clean the surface of the battery regularly. During the operation of the battery, dust and traces left by the overflow of the electrolyte may accumulate on its surface. These dirt may cause short circuits between the terminals, affecting the performance of the battery. Therefore, the surface of the battery should be wiped regularly with a clean damp cloth to remove dirt and dust. However, it is necessary to avoid moisture from entering the battery interior to prevent short circuits.

2. Check the tightness of the connecting terminals. As the forklift vibrates during operation, the connection terminals of the battery may gradually loosen. Regularly inspecting and tightening the connection terminals can ensure the reliability of electrical connections, reduce contact resistance, and prevent sparks caused by poor contact. When fastening the terminals, use appropriate tools to avoid damaging the terminals due to excessive force.

3. Regularly conduct performance tests on the battery. Professional battery testing equipment can be used to test parameters such as the capacity, voltage and internal resistance of the battery to understand its performance status. Based on the test results, adjust the charging strategy in a timely manner or maintain and service the battery. For batteries with severely declined performance, they should be replaced in a timely manner to ensure the normal operation and operational safety of the forklift.

4. Emergency Response Measures

(1) Electrolyte leakage Treatment

When electrolyte leakage occurs, protective measures should be taken immediately. Operators must wear acid and alkali resistant gloves, goggles and protective clothing and other protective equipment to prevent the electrolyte from coming into contact with the skin and eyes. If the electrolyte accidentally comes into contact with the skin, it should be immediately rinsed with plenty of water for more than 15 minutes and medical attention should be sought promptly. If it comes into contact with the eyes, immediately open the eyelids, rinse with plenty of water, and seek medical treatment at a hospital as soon as possible.

For leaked electrolyte, alkaline substances such as lime and baking soda can be used for neutralization. Evenly sprinkle the alkaline substances on the leaked electrolyte to cause a neutralization reaction. Then, use a broom and dustpan to clean up the neutralized substances and properly handle them. The waste generated during the cleaning process should be treated as hazardous waste and must not be discarded at will to avoid environmental pollution.

(2) Emergency Response to Fire and Explosion

In the event of a fire or explosion accident, the on-site personnel should immediately activate the emergency response plan. First of all, quickly cut off the power supply of the forklift and the charging equipment to prevent the spread of fire and secondary accidents. Then, use a dry powder fire extinguisher or a carbon dioxide fire extinguisher to put out the fire. It is strictly prohibited to use water to extinguish fires, as lead-acid battery fires may be accompanied by electrolyte leakage. Water can cause the electrolyte to spread, accelerating corrosion and pollution, and may also lead to electric shock accidents.

During the process of extinguishing a fire, pay attention to your own safety and avoid inhaling smoke and toxic gases. If the fire is too large to be controlled, immediately call the fire department to report it and organize personnel to evacuate to a safe area to ensure the safety of people's lives. After the fire is extinguished, a comprehensive inspection of the scene should be carried out to identify the cause of the accident. Damaged batteries and equipment should be properly handled to prevent the recurrence of the accident.

(3) Emergency Treatment for Personnel Poisoning

Lead-acid batteries produce a small amount of harmful gases during charging and discharging, such as hydrogen and sulfur dioxide. If one works for a long time in a poorly ventilated environment, it may cause poisoning of personnel. When someone shows symptoms of poisoning such as dizziness, nausea and breathing difficulties, the poisoned person should be immediately moved to a well-ventilated area, and their collar and belt should be unfastened to ensure smooth breathing.

If the poisoning symptoms are mild, the poisoned person can be allowed to breathe fresh air. After resting for a period of time, the symptoms usually gradually ease. If the symptoms are severe, you should call the emergency number immediately and be sent to the hospital for treatment. At the same time, the working environment should be fully ventilated to improve air quality and prevent other personnel from being poisoned.

5. Conclusion

The safe use of lead-acid batteries in forklifts is a systematic project, involving multiple links such as preparation and inspection before use, safe operation during use, and emergency handling. Only by strictly adhering to all safety usage precautions, doing a good job in daily maintenance and upkeep, and enhancing the safety awareness and operational skills of operators, can the safe and stable operation of lead-acid batteries be ensured, their service life be prolonged, the efficient operation of forklifts be guaranteed, and at the same time, safety accidents and environmental pollution problems caused by improper use of batteries be avoided. Provide reliable safety guarantees for the production and operation activities of enterprises. In practical work, enterprises should continuously strengthen the management and training of the safe use of lead-acid batteries in forklifts, establish and improve relevant rules and regulations and emergency plans, and truly implement the safe use work to promote the safe and sustainable development of the logistics and warehousing industry.