As lithium-ion powered forklifts are widely applied in modern logistics and manufacturing scenarios, non-standard battery replacement operations may easily trigger hidden risks including overheating, electrolyte leakage and accidental electric shock. Implementing standardized, compliant battery handling procedures can effectively eliminate most hidden safety hazards on site, and extend the service life of related supporting equipment.

Pre-operation preparation

All on-site operators must complete corresponding safety skill training before conducting any battery replacement work, and wear complete personal protective equipment including insulated gloves, anti-slip safety shoes and impact-resistant goggles. The designated operation area should be kept ventilated, all flammable and explosive items should be moved away from the working range, and special fire fighting equipment for electrical and metal fire scenarios must be placed within easy reach. Before starting the replacement process, operators should first turn off the forklift’s total power switch, pull out the key to cut off the whole circuit, and make a preliminary appearance inspection for the old battery, to confirm no bulging, cracking or electrolyte exudation phenomenon exists.

Standardized replacement operation

When removing the old lithium-ion battery, operators must use special handling equipment that matches the rated weight of the battery, and it is forbidden to drag, roll or drop the battery forcibly on the ground. Do not place sharp metal tools on the top surface of the battery in case of accidental short circuit. When installing the new battery, align the positioning slider of the battery compartment slowly, and push the battery to the fixed position gently. It is not allowed to pry the power interface with hard tools to avoid damage to the sealing structure. After the battery is in place, check that all connecting buckles are locked firmly, and no exposed loose wires are left around the connection part.

Post-operation safety confirmation

The removed old battery should be transported to the special insulated storage area immediately, and it is forbidden to stack waste batteries in the passageway or near the heat source. Operators need to fill in the battery replacement record form truthfully, mark the status of the replaced battery, and arrange subsequent professional transfer treatment. After the whole replacement process is finished, do a 5-minute no-load test run of the forklift, check whether the battery temperature and voltage data are within the normal operation range, and clean up all tools and sundries in the operation site. Regularly carry out safety procedure review and skill retraining for relevant personnel, can help form good operation habits, and ensure the long-term stable and safe operation of all lithium-ion forklift equipment in the work site.