Safe operation and maintenance procedures for electric forklifts

Safe operation and maintenance of electric forklifts

Related systems and responsibility for maintaining safe operating rules for electric forklifts. Rules and procedures for safe operation.

Safe forklift operation procedures

Electric forklifts and internal combustion forklifts are nearly identical in shape and construction, respectively. But there is a difference in the exact operation method: Since the drive speed and direction of motion of the electric forklift is achieved by changing the current and changing the direction of rotation of the motor, so:

It has no mechanical clutch device and is controlled directly by the accelerator (electrical accelerator). Direction switches are used to change the steering direction (forward or reverse) of the forklift. The drive motor has no idle speed and the forklift starts up as soon as the electric motor operates. Its speed is controlled by the synchronizer. The working equipment (fork and tilt) of an electric forklift is the same as that of an internal combustion forklift.

The operation method of electric forklift trucks is basically the same. However, due to the difference in design and construction, they also have their own characteristics. During operation, it must be operated according to the specifications and operating sequence, otherwise the control system will protect itself and cannot work properly. The number of operations and the weight of each mechanism must be passed several times to achieve proficiency, accuracy and safety.

Safety steps when operating an electric forklift

Before working, drivers should wear protective clothing according to regulations.

Shoes for the following technical test and operation for electric forklifts:

Check the electrolyte level and specific gravity of the battery. The liquid level of the electrolyte in the battery shall not be lower than the separator. The specific gravity of the electrolyte must meet the requirements. The voltage of the battery shall not be less than the specified voltage and the specific gravity of the electrolyte shall not be less than the specified specific gravity. The electric forklift control system has the function of protecting the life of the battery: When the electricity on the meter shows overvoltage protection, it is necessary to charge it in time, clean and tighten the electrode joints.
Check the power line. All wiring connections should be tight and in good contact, fuses and fuses should be in good condition, and each switch and handle should be in the stopped position.
Close the emergency stop switch, open the ignition and check that appliances, lights, speakers, etc. Is it working normally?
Check the steering mechanism, it should be flexible and light.
Check the brake device, it should be flexible and reliable.
Check that the bearings and related running parts are well lubricated and flexible.
Check the forklift’s travel and hydraulic system for normal operation, especially the pipelines, couplings, oil cylinders, distribution valves, etc. Is there an oil leak in the hydraulic components?
Check to ensure that the shock absorber, presser mechanism, horizontal mechanism, lifting chain, truss, etc. are in good working order and reliable in use.
Find bugs, remove them promptly and never drive out with bugs.

Notes on starting and driving an electric forklift
Before driving, the driver should first check and clean the site and aisle to be suitable for forklift operation.
Correct sequence of operations when starting: sit in the driver’s seat with the correct posture → close the emergency stop switch → the diverter switch and the accelerator pedal are in a relaxed state → unlock the electric lock → release the handbrake → correct the position of the vehicle. change direction → tap the accelerator step by step → honk the horn → start slowly and accelerate gradually. It is strictly forbidden to step on the accelerator more than 20% without turning on the ignition, otherwise the control system will appear “high pedal” protection. The forklift fails to start when “operation sequence” and “high pedal” “Protection fault occurs, turn off the ignition switch, re-implement the above operating sequence correctly, the fault will automatically be eliminated.
When driving, you should accelerate gradually, and do not leave the vehicle at low speeds for long periods of time.
It is strictly forbidden to move the navigation switch while driving, only after the vehicle has come to a complete stop. Flip the direction switch to change direction so try to avoid. Do not apply emergency braking. In an emergency, the emergency stop switch must be quickly turned off and the electric lock must be turned off.
Horn when starting or turning when turning, going downhill, uneven road or through narrow road, slow down and drive slowly.
When driving on the road that needs to be overtaken on the right, the forklift fork is about 200-300mm above the ground, the rig is in a backward inclined position. When two vehicles are driving in the same direction, the distance between front and rear should be kept above 5m.
When multiple forklift trucks run on the same platform, the distance between the front and rear should be more than 5m, and it is strictly forbidden to run parallel on the narrow platform in the same direction, and the distance from the edge of the platform should be more than 300mm.
When forklifts and tractors are towing trailers, do not follow a continuous curve to avoid high discharge affecting safety. No need to carry full load, no load, uphill, downhill… It is strictly forbidden to drive in reverse, when turning red

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FAQs about Forklift
Frequently Asked Questions about Forklifts 1. What is a forklift? Answer: A forklift is a specialized vehicle designed to lift, lower, and move goods and materials in warehouses and factories easily and safely. It is equipped with front lifting forks and an engine for movement. 2. What are the most common types of forklifts? Answer: Some common types of forklifts include counterbalance forklifts, electric forklifts, pneumatic forklifts, and manual pallet jacks. Among them, electric forklifts are the most popular due to their flexibility, ease of use, and environmental friendliness. 3. What is the typical lifting range of a forklift? Answer: The standard lifting range of a forklift is usually between 2m – 5.5m depending on the type and capacity. For high-rise warehouses, taller lifting ranges up to 7-12 meters can be used. 4. What is the maximum safe load capacity of regular forklifts? Answer: The safe load capacity of regular forklifts ranges from 1 – 5 tons depending on the capacity and size of the vehicle. For heavy-duty forklifts, the load capacity can go up to 10-15 tons. Always follow the manufacturer’s recommended load limits to ensure safety. 5. What are the common fuel options for forklifts? Answer: Forklifts commonly run on electricity (battery) or diesel/gasoline fuel. Electric forklifts are preferred in indoor warehouses due to their clean operation, quietness, and ease of use. 6. How should a forklift be regularly maintained? Answer: To ensure proper operation and safety, a forklift should undergo regular maintenance every month or after a certain number of operating hours. Maintenance tasks typically include checking oil levels, replacing oil/fuel filters, inspecting brakes/tires, charging/replacing batteries (for electric forklifts), etc. 7. How much does it cost to operate and maintain a forklift annually? Answer: The annual operating and maintenance cost for a regular forklift is around 15 – 30 million VND, including fuel costs (diesel, gasoline, electricity), regular maintenance, and small component replacements. For higher-end forklifts, the cost can go up to 50-70 million VND per year. 8. How to safely lift and lower palletized loads with a forklift? Answer: When lifting loads, tilt the forks forward by 15 degrees to ensure stability, move slowly, and maintain a safe distance from the surroundings. Lift the load slowly according to the driver’s visibility. Lower the load slowly in a tilted direction. Avoid sudden lifting or lowering that may cause load spills. 9. What qualifications or certifications are required to operate a forklift? Answer: Forklift operators need to have certification in safe operation and handling of forklifts. They also need to possess a Forklift Driver’s License issued by the authorized agency to legally operate the vehicle. 10. What are the standard dimensions of different types of forklifts? Answer: The dimensions of forklifts vary depending on their load capacity and type. Typically, length ranges from 1.5 – 3m; width ranges from 0.5 – 1m; height ranges from 1.5 – 4m. Some models have smaller dimensions to fit narrow aisles. 11. On what types of terrains can forklifts operate? Answer: Forklifts can operate well on most flat surfaces such as concrete, asphalt, tiled floors, etc. However, they should not be used on rough or uneven terrains or muddy areas. 12. What is the safe traveling speed of a forklift when carrying loads? Answer: The recommended safe traveling speed for a forklift carrying loads is 8-12 km/h. Speed should be reduced when going around corners or narrow paths. 13. How to stack loads on a forklift to ensure safety? Answer: Loads should be stacked evenly and within the allowed load capacity. Do not stack higher than the fork height. Maintain stability while moving. Stack in a way that does not obstruct the driver’s visibility. 14. What safety features do forklifts have? Answer: Forklifts are equipped with reverse alarms, turn signals, warning horns, anti-tip frames, and guardrails to protect the driver and cargo. 15. How long does it take to fully charge an electric forklift battery? Answer: The average charging time for an electric forklift battery is 6-8 hours. It should be fully charged before each shift. Some models can have fast charging options within 2-3 hours. 16. Which countries are the most common sources of imported forklifts? Answer: Forklifts are mostly imported from Japan, South Korea, China, and Taiwan. These countries are known for their quality and popular brands in Vietnam. 17. What are some popular forklift brands? Answer: Some popular forklift brands include Toyota, Mitsubishi, Komatsu, Nissan, TCM, Hangcha, Lonking… 18. Is it better to buy a new or used forklift? Why? Answer: It is recommended to buy a new forklift to ensure quality and longevity of the vehicle. New forklifts have high durability, fewer breakdowns, and lower maintenance costs. Used forklifts may be cheaper but come with higher risks of issues. 19. How much does it cost to insure a forklift annually? Answer: The insurance cost for a forklift is around 4-8% of the vehicle’s value. For example, for a 500 million VND forklift, the insurance fee would be approximately 20-40 million VND per year depending on the coverage. 20. What is the process for inspection and registration of a forklift? Answer: Forklifts need to undergo inspection and registration procedures according to local regulations. This typically involves submitting necessary documents, paying fees, and obtaining registration plates or stickers.
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