Safety Operation Manual for Lithium-Ion Battery Electric Forklifts

1. General Provisions

1.1 Purpose

1.2 Scope of Application

1.3 Core Principles

• Operators must receive professional training and pass assessments before taking up their posts.
• Strictly abide by the operating specifications of "inspect first, then operate; power off first, then maintain".
• Operations related to lithium-ion batteries (charging, inspection, fault handling) must strictly follow the original manufacturer's requirements. Unauthorized modification or disassembly is prohibited.

2. Pre-Operation Preparation

2.1 Personnel Preparation

• Operators shall wear labor protection equipment that meets requirements, including anti-smashing safety shoes and non-slip gloves. Wearing slippers, high-heeled shoes, or loose clothing during operation is strictly prohibited.
• Before operation, operators shall confirm that they are in good physical condition, without fatigue, intoxication, illness, or other conditions that may affect operation. Operating under the influence of alcohol or while ill is strictly prohibited.

2.2 Equipment Inspection

Battery System Inspection

• Check the appearance of the battery pack for abnormalities such as bulging, deformation, cracks, and liquid leakage (corrosive liquid).
• Inspect the battery interfaces and circuit connectors for looseness, oxidation, or damage, and ensure the interfaces are clean and free of dust.
• After starting the forklift, confirm that the battery voltage and temperature displayed on the instrument panel are normal (voltage within the rated range, temperature < 50℃), and there are no prompts such as "battery fault" or "high-temperature alarm".

Forklift Function Inspection

• Test the braking system to ensure the brake pedal stroke is normal, the braking is sensitive and effective, and there is no deviation.
• Inspect the hydraulic system to ensure the fork lifting and tilting movements are smooth without jamming or abnormal noise, and the hydraulic pipelines have no leakage.
• Confirm that the lights (headlights, turn signals, warning lights) and horn function normally, the rearview mirrors are adjusted properly, and the field of vision is clear.

Working Environment Inspection

• Ensure the ground in the operation area is free of water, oil stains, and obstacles, and the channel width meets the forklift driving requirements (at least 1.5 times the width of the forklift).
• Ensure there are no open flames or flammable and explosive materials (such as cartons, paint, gasoline) in the operation area, and the ventilation is good. If operating in cold storage or high-temperature workshops, confirm that the forklift's temperature control function is normal.

3. Operation Specifications

3.1 Start-Up Operation

• ｉｎｓｅｒｔ the key or activate the start button, wait for the instrument panel self-inspection to complete (about 3-5 seconds), and confirm there is no fault alarm before operating.
• Press the brake pedal, switch the forward/backward direction switch, release the handbrake, slowly lift the brake pedal, and gently step on the accelerator pedal to start the forklift.
• After starting, drive at a low speed for 1-2 meters first to test whether the braking and steering functions are normal. Proceed to normal operation only if there is no abnormality.

3.2 Driving Operation

• Driving speed: No more than 10 km/h when unloaded, and no more than 5 km/h when loaded. When turning, passing through intersections, or in crowded areas, reduce the speed to below 2 km/h and sound the horn to warn.
• Driving route: Avoid crowded areas and narrow passages; reverse driving is prohibited. At crossroads, follow the principle of "slow down first, look second, pass third", and stop to observe if necessary.
• Special road conditions: Avoid driving on waterlogged roads (water depth not exceeding 1/3 of the tire height) or steep slopes (slope not exceeding the rated climbing angle of the forklift). When going up or down slopes, drive straight at a low speed; shifting gears and turning are prohibited.
• Prohibited behaviors: Sudden acceleration and sudden braking during driving are prohibited to avoid instantaneous high-current impact on the battery. Carrying passengers (other than the driver) is prohibited, and extending body parts outside the vehicle is prohibited.

3.3 Loading and Unloading Operation

• Before loading and unloading, park the forklift steadily directly in front of the goods, pull the handbrake, and confirm that the goods are stacked stably without tilting.
• Adjust the distance between the forks so that they are symmetrically distributed on both sides of the center of gravity of the goods. The insertion depth of the forks into the bottom of the goods shall not be less than 2/3 of the length of the goods to avoid one-sided stress.
• Slowly lift the forks to make the goods 10-15 cm off the ground. After confirming the goods are stable, slowly tilt the forks (the forward/backward tilting angle shall not exceed 15°) to prevent the goods from slipping.
• During transportation, the height of the goods shall not exceed the driver's field of vision. If it is necessary to transport ultra-high goods, a person shall guide in front. Overloading is prohibited, and the weight of the goods shall not exceed the rated load capacity of the forklift.
• When unloading, slowly lower the forks to the ground. After the goods are placed stably, slowly pull out the forks. Suddenly pulling or forcing the forks out is prohibited.

3.4 Shutdown Operation

• After the operation is completed, drive the forklift to the designated parking area, park it on a flat ground, and pull the handbrake.
• Lower the forks to the ground, turn off the hydraulic system, switch the direction switch to "neutral", and turn off the power (pull out the key or turn off the start switch).
• Inspect the appearance of the forklift, clean up the debris on the forks, and lock the door (if any) after confirming there is no abnormality.

4. Charging Safety Specifications

4.1 Pre-Charging Preparation

• Only use the original supporting special charger for lithium-ion batteries. Using lead-acid battery chargers or non-original chargers is prohibited.
• The charging area shall be well-ventilated, free of open flames, with the temperature controlled between 0-40℃, and far away from flammable and explosive materials. Long-term charging in enclosed spaces (such as basements, warehouse corners) is prohibited.
• Check whether the charger interface and battery interface are damaged, oxidized, or loose. Clean the dust and debris on the interfaces with a dry cloth to ensure good contact.

4.2 Charging Process Operation

• First connect the charger plug to the forklift battery interface, then ｉｎｓｅｒｔ the charger power plug into a well-grounded socket. Reverse operation (connecting the power first and then the battery) is prohibited.
• During charging, confirm that the charger indicator light displays normally (usually red for charging status), with no abnormal heating, noise, or peculiar smell. If the indicator light flashes or an error is reported, stop charging immediately, check the interface, or contact maintenance personnel.
• During charging, plugging and unplugging the interface, moving the forklift or charger are prohibited. Covering the charger or battery pack is prohibited to maintain smooth heat dissipation.
• "Charge as you use" is supported; there is no need to wait for the battery to be fully discharged. However, frequent short-term charging (no more than 3 times a day) should be avoided to extend the battery life.

4.3 Post-Charging Operation

• When the charger indicator light turns green (full charge status), continue trickle charging for 30 minutes, then disconnect the power.
• First unplug the charger power plug, then unplug the battery interface plug to avoid sparking. Arrange the charger properly and store it in the designated location.
• Check whether the battery interface is heated or oxidized. After cleaning, close the battery compartment door (if any), and record the charging time and battery status.

5. Maintenance Specifications

5.1 Daily Maintenance (Before and After Daily Operation)

• Clean the appearance of the forklift, wipe off dust and oil stains on the forks and body, and clean up debris at the battery interface.
• Inspect the appearance of the battery pack for bulging, deformation, or liquid leakage, and check that the interfaces are free of looseness or oxidation.
• Check the hydraulic pipelines and braking system for leakage or abnormal noise, and ensure the brake pedal stroke is normal.
• Record the forklift operation status and battery endurance. If abnormalities are found (such as sudden ｄｒｏｐ in endurance, brake failure), stop using the forklift immediately and report.

5.2 Regular Maintenance (Weekly/Monthly)

Weekly Maintenance

• Check whether the fixing bolts of the battery pack are loose, and tighten any loose parts.
• Test the functions of the forklift lights, horn, and warning lights, and ｒｅｐｌａｃｅ damaged parts.
• Check the hydraulic oil level; if it is below the standard line, add hydraulic oil of the same model.

Monthly Maintenance

• Check the battery insulation resistance to ensure there is no leakage (professional personnel can be contacted for testing).
• Clean the hydraulic system filter and ｒｅｐｌａｃｅ deteriorated hydraulic oil (according to the manufacturer's recommended cycle).
• Check the tire air pressure and wear condition, and ｒｅｐｌａｃｅ damaged or excessively worn tires.

5.3 Prohibited Items

• Unauthorized disassembly of the battery pack, controller, or charger is prohibited. If maintenance is required, contact personnel authorized by the manufacturer.
• Unauthorized modification of battery circuits, replacement of battery cells or chargers is prohibited. Adding any chemical reagents to the battery is prohibited.
• Cleaning the battery pack or interfaces with water or organic solvents is prohibited to avoid water ingress and short circuit.
• After the battery reaches its service life (usually 5-8 years) or cycle life (2000-3000 times), contact the manufacturer for recycling and replacement. Continuing to use or discarding the battery at will is prohibited.

6. Emergency Response Procedures

6.1 Emergency Response for Battery Fire

• Immediately stop the forklift operation, disconnect the charger (if charging is in progress), and evacuate personnel around to a safe area.
• Use a dry powder fire extinguisher or carbon dioxide fire extinguisher to spray at the fire source. Using water or foam fire extinguishers is prohibited (lithium-ion batteries may intensify the reaction when in contact with water).
• If the fire cannot be controlled, call the fire alarm immediately, inform the firefighters that "a lithium-ion battery electric forklift is on fire", and explain the on-site situation.

6.2 Emergency Response for Battery Leakage

• After discovering battery leakage, stop using the forklift immediately, wear acid and alkali-resistant gloves and goggles, and avoid direct skin contact with the leaked liquid.
• Absorb the leaked liquid with dry sand or absorbent cotton. The collected leaked liquid shall be put into a corrosion-resistant container and contacted with the manufacturer for recycling and treatment. Random dumping is prohibited.
• Clean the leaked area, confirm there is no residue, then contact maintenance personnel to inspect the battery. Continuing to use the battery is prohibited.

6.3 Emergency Response for Electric Shock

• If an operator is electrocuted, immediately cut off the power (unplug the charger, turn off the main switch), or use insulated tools such as dry wooden sticks or plastic sticks to separate the electrocuted person from the power source.
• Check the electrocuted person's consciousness and breathing. If the person is unconscious or has difficulty breathing, immediately perform cardiopulmonary resuscitation and call the 120 emergency number.
• After the incident, check the insulation condition of the forklift, investigate the cause of leakage, and use the forklift again only after it is repaired and qualified.

6.4 Emergency Response for Collision/Fault

• After a forklift collision, immediately stop the operation, check whether personnel are injured, and send the injured to the hospital immediately if there are any.
• Inspect whether the battery pack and vehicle body structure are damaged. If the battery pack shell is deformed or the battery cells are exposed, evacuate the site immediately, contact the manufacturer for handling, and prohibit starting the forklift.
• If the forklift has faults such as brake failure or hydraulic failure, stop the operation immediately, use a triangular warning sign to warn surrounding personnel, contact maintenance personnel for emergency repair, and prohibit forced operation.

7. Supplementary Provisions

7.1 Training Requirements

• All operators must participate in professional safety training, be familiar with the content of this manual, master operating skills and emergency response methods, and can take up their posts only after passing the assessment. Re-training shall be conducted at least once a year to ｕｐｄａｔｅ safety knowledge.

7.2 Responsibility Division

• Operators are responsible for the safety of daily operations, strictly abide by the operation specifications in this manual, and report in a timely manner when abnormalities are found.
• Equipment managers are responsible for forklift maintenance, battery management, and organizing regular safety inspections to ensure the equipment meets safety requirements.
• The user unit shall conduct regular safety publicity and education, be equipped with necessary emergency materials (fire extinguishers, first-aid kits, acid and alkali-resistant gloves, etc.), and implement safety management responsibilities.

7.3 Manual ｕｐｄａｔｅ

• This manual shall be updated once a year according to the forklift model, manufacturer's requirements, and actual use conditions. If there are major technical changes or safety specification adjustments, it shall be revised in a timely manner and informed to relevant personnel.