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In the field of modern industrial logistics, forklifts, as important handling equipment, are widely used in warehousing, transportation and other links. Lead-acid batteries, as the main power source for forklifts, will gradually decline in performance with the increase of usage time. When the battery capacity cannot meet the normal working requirements of the forklift, it needs to be replaced. The process of replacing lead-acid batteries in forklifts involves multiple safety risks such as electrical and mechanical operations as well as the handling of chemical substances. Adopting multi-person collaborative operations not only enhances work efficiency but also effectively reduces the probability of safety accidents. This article will provide a detailed analysis of the safety regulations for the replacement of lead-acid batteries in forklifts and the operation process of multi-person collaboration, offering comprehensive and referential guidance for practical work.

1. Preparations before operation

(1) Personnel Division of Labor and Training

Clarify personnel division of labor: In multi-person collaborative operations, the first step is to clarify the responsibilities of each member. Generally speaking, one team leader can be appointed to be responsible for the command, coordination and on-site safety supervision of the entire replacement process. Two to three battery handlers are needed, mainly responsible for the loading, unloading and transportation of batteries. One electrical operator is needed, responsible for the disassembly and installation of the battery's electrical connection part. One to two support staff members are needed to assist in tasks such as tool transfer and on-site debris clearance.

Safety training: Before officially starting the job change, all participants must receive comprehensive safety training. The training content includes the basic structure and working principle of lead-acid batteries, knowledge of forklift electrical systems, safety risks and preventive measures during the replacement process, and emergency response methods for critical situations, etc. Through training, ensure that each personnel is familiar with the operation procedures and safety requirements and has the ability to deal with emergencies.

(2) Preparation of equipment and tools

Handling equipment: Prepare appropriate handling equipment, such as electric forklifts, hydraulic pallet trucks, etc., to ensure they are in good working condition and have sufficient load-bearing capacity to handle lead-acid batteries. The handling equipment should be maintained and inspected regularly to prevent accidents such as battery drops caused by malfunctions during the handling process.

Specialized tools: Fully prepared specialized tools, including insulating gloves, insulating wrenches, goggles, acid and alkali resistant gloves, acid and alkali resistant aprons, acid-absorbing cotton, leak-proof containers, etc. These tools not only ensure the safety of the operators, but also effectively prevent the leakage of battery electrolyte from polluting the environment. At the same time, check whether the tools are intact and undamaged, and whether the insulation performance of the insulated tools is good.

New battery inspection: Conduct a comprehensive inspection of the new lead-acid batteries that are about to be replaced. Check if there is any damage or leakage on the battery's appearance, verify if the battery model and specification match the forklift, and check the production date and warranty information of the battery to ensure that the new battery is reliable in quality and meets the performance requirements.

(3) On-site environment preparation

Site selection: Choose a spacious, well-ventilated and dry site for the battery replacement operation. The site should be kept away from fire sources, heat sources and flammable and explosive items. Work should be avoided in high-temperature, humid or corrosive gas environments. At the same time, ensure that there is sufficient space around the site for the transportation of equipment and personnel movement to prevent accidents such as collisions caused by narrow space.

Warning sign setting: Clear warning signs such as "No Smoking or Fire" and "Dangerous area, Please do not Approach" should be set up around the change work site. When necessary, isolation belts should be set up to restrict irrelevant personnel from entering the work area and prevent accidents.

2. Multi-person collaborative operation process

(1) Removal of old batteries

Forklift parking and power-off: Under the command of the team leader, drive the forklift to the designated replacement site, park it on a flat and solid ground, pull the handbrake, and ensure the forklift is in the braking state. Electrical operators should wear insulating gloves, turn off the main power switch of the forklift, disconnect all electrical connections related to the battery, such as power lines and control lines, and insulate the disconnected wire ends to prevent short circuits.

Battery fixing device disassembly: Battery movers and auxiliary personnel cooperate to use appropriate tools to remove the battery fixing device, such as bolts, clips, etc. During the disassembly process, it is necessary to pay attention to recording the disassembly sequence and position of the fixing device so that it can be correctly reset when installing a new battery later. Meanwhile, it is necessary to prevent the fixed device from falling and injuring people or damaging other equipment.

Battery handling: After removing the fixing device, use handling equipment to slowly and smoothly remove the old battery from the forklift. During the handling process, battery handlers should closely cooperate to maintain the balance and stability of the handling equipment and prevent the batteries from tilting or shaking. Auxiliary personnel are on the side to supervise and promptly remind the movers to pay attention to the surrounding environment and prevent collisions with other objects. Transport the used batteries to the designated storage area, where measures should be taken to prevent leakage and corrosion.

(2) Installation of new batteries

Battery positioning: Move the new battery to the vicinity of the forklift battery installation position. The battery movers and assistants cooperate to accurately place the new battery in the installation slot based on the size and shape of the forklift battery installation slot. During the placement process, pay attention to the positive and negative pole directions of the battery to ensure the correct connection with the forklift's electrical system.

Installation of the fixing device: Install the battery's fixing device in the order and position recorded during disassembly. Use tools to tighten and fix the bolts, clips, etc., to ensure that the battery is firmly installed and will not loosen or shift during the forklift's operation. Electrical operators are on the side to conduct inspections and provide guidance to ensure that the battery installation meets the requirements.

Electrical connection: Electrical operators should wear insulating gloves and correctly connect power lines, control lines, etc. to the positive and negative terminals of the new battery in accordance with the wiring diagram of the forklift's electrical system. During the connection process, it is necessary to ensure that the connection is firm and the contact is good, and avoid phenomena such as loosening and loose connection. After the connection is completed, check again whether all the electrical connections are correct and whether there are any problems such as short circuits or open circuits.

(3) Inspection and Debugging

Comprehensive inspection: After the new battery is installed, the team leader shall organize all participants to conduct a comprehensive inspection of the battery replacement work. The inspection items include whether the battery fixing device is installed firmly, whether the electrical connection is correct, and whether the tools and debris are cleaned up thoroughly, etc. At the same time, check whether other components of the forklift have been affected during the battery replacement process. If any abnormal situation is found, handle it promptly.

Commissioning and operation: After checking for accuracy, the electrical operator turns on the main power switch of the forklift, starts the forklift, and conducts a simple commissioning and operation. Observe whether the forklift's start-up, traveling, lifting and lowering functions are normal, and check whether the battery's voltage, current and other parameters are within the normal range. In case of any abnormal situation, immediately stop the forklift operation and carry out fault investigation and repair.

4. Safety Precautions

(1) Electrical safety

When performing electrical connection and disassembly operations of batteries, insulating gloves and goggles must be worn, and insulating tools must be used to prevent electric shock accidents.

Disconnected electrical wire ends should be insulated in a timely manner to prevent short circuits from causing fires or other safety accidents. When inspecting electrical connections, it is strictly forbidden to touch exposed electrical joints directly with your hands.

(2) Chemical Safety

The electrolyte in lead-acid batteries is highly corrosive. Operators must wear acid and alkali resistant gloves, acid and alkali resistant aprons and goggles and other protective equipment to prevent the electrolyte from splashing onto the skin and eyes. In the event of electrolyte leakage, acid-absorbing cotton should be used immediately for adsorption treatment, and the contaminated items should be placed in leak-proof containers and properly disposed of in accordance with relevant regulations.

In case of accidental contact with the electrolyte, rinse immediately with plenty of water and seek medical treatment promptly. The site for battery replacement should be equipped with emergency flushing facilities, such as eye wash stations and showers, for use in emergency situations.

(3) Mechanical Safety

When using handling equipment to move batteries, operations must be carried out strictly in accordance with the equipment's operating procedures. Overloading and speeding are strictly prohibited. The operators of the handling equipment should undergo professional training and be familiar with the performance and operation methods of the equipment.

When disassembling and installing the battery mounting device, be sure to prevent tools from falling and injuring people or damaging other equipment. When multiple people collaborate to move batteries, they should be under unified command, cooperate with each other, and maintain coordinated movements to avoid battery drops or injuries due to uneven force application.

5. Emergency Response Measures

Emergency response for electric shock accidents: In the event of an electric shock accident, the power supply should be cut off immediately. Use an insulating object to separate the person who has been electrocuted from the live equipment. It is strictly forbidden to touch the person directly with hands. Provide on-site first aid to the person who has been electrocuted, such as performing cardiopulmonary resuscitation, and promptly call the emergency number to send them to the hospital for treatment.

Emergency response for electrolyte leakage: When electrolyte leakage occurs, operations should be immediately halted, personnel on site evacuated, and the leaked electrolyte treated with acid-absorbing cotton, neutralizers, etc. Clean up the contaminated ground and items thoroughly and dispose of them in accordance with the regulations for hazardous waste treatment. Meanwhile, ventilation treatment should be carried out in the leakage area to prevent the accumulation of harmful gases.

Emergency response to fire accidents: In the event of a fire accident, the fire extinguishers provided on the scene should be used immediately to put out the fire, and the fire alarm number should be called promptly. In the early stage of a fire, it is necessary to organize the evacuation of personnel to ensure their safety. If the fire is too large to be controlled, evacuate the scene quickly and wait for the rescue of the firefighters.

In conclusion, the replacement of lead-acid batteries in forklifts is a task with certain risks. By strictly adhering to safety regulations, adopting scientific and reasonable multi-person collaborative operation procedures, making adequate preparations, strengthening the implementation of safety precautions, and formulating comprehensive emergency response measures, the safety and smooth progress of battery replacement work can be effectively guaranteed, and work efficiency can be improved. Reduce the occurrence of safety accidents and provide reliable guarantees for the production and operation of enterprises.