"Forklift suddenly smoking while charging" "Warehouse catching fire due to forklift battery at midnight" – such safety accident news makes many logistics professionals worry about the safety of electric forklift charging. In fact, over 90% of charging accidents are not caused by equipment itself, but by non-standard operations. As long as you master the core operating standards, electric forklift charging can achieve "zero risk". Today, we will break down 5 mandatory standards to build a solid safety barrier for charging.

Standard 1: "Three Checks" Before Charging – Eliminate Hidden Risks from the Source

Inspection before charging is the first safety barrier; missing any item may trigger risks. Focus on three core aspects:

• Check Battery Condition: Observe if the battery case is bulging, damaged, or leaking. If electrolyte leakage (lead-acid batteries) or battery swelling (lithium-ion batteries) is found, stop using it immediately, contact professionals for maintenance, and strictly prohibit charging damaged batteries.

• Check Charging Equipment: Inspect if the charger plug and power cord are damaged or aged, and if the interface is loose or oxidized. If copper wires are exposed or contact is poor, replace with regular accessories in time to avoid short-circuit and fire.

• Check Charging Environment: Ensure the charging area is well-ventilated (to discharge trace gases from lithium-ion battery charging), free of flammable and explosive materials (such as cartons, oily rags), with dry ground without water accumulation, and away from open flames and high-temperature sources (such as radiators, welding areas).

Standard 2: "Three Don'ts" During Charging – Avoid Unattended Risks

The charging process is a high-risk period; in particular, the mentality of "letting it be" must be avoided. Keep in mind the "three don'ts principle":

• Don't Leave Unmonitored: A single charging cycle usually takes 8-10 hours (lead-acid batteries) or 1-2 hours (fast-charging lithium-ion batteries). Patrol every 2 hours during charging, focusing on battery temperature (normally not exceeding 45℃) and whether the charger is abnormally hot.

• Don't Mix Randomly: It is strictly prohibited to charge a Brand B battery with a Brand A charger, or a fast-charging battery with a regular charger. Mismatched voltage and current between different types of batteries and chargers can easily cause overload and short-circuit.

• Don't Operate Illegally: It is forbidden to start the forklift for driving or operate the forks during charging. Do not disassemble the battery cover or plug/unplug the charging plug without permission; turn off the charger power before plugging or unplugging.

Standard 3: "Three Clean-Ups" After Charging – Complete Post-Charging Protection

Charging completion is not the end; standard post-charging procedures can avoid subsequent hidden risks. Focus on the "three clean-ups":

• Clean Up Equipment: Turn off the charger switch first, then unplug the battery-side plug, and finally disconnect the power supply. Arrange the power cord properly (to avoid crushing and winding) and clean the dust on the charger surface.

• Clean Up the Site: Remove debris in the charging area. Check if there is any spilled electrolyte (lead-acid batteries) on the ground; if so, neutralize it with baking soda water and wipe it clean to prevent floor corrosion or electric shock.

• Clean Up Records: Record the charging start time, end time, and battery status in the "Forklift Charging Log". If abnormalities are found (such as significantly prolonged charging time, battery heating), mark them prominently and report.

Standard 4: "Two Regulars" for Battery Maintenance – Extend Lifespan and Enhance Safety

The health status of the battery directly affects charging safety; regular maintenance is essential. Focus on two key tasks:

• Regularly Inspect Battery Performance: For lead-acid batteries, check the electrolyte level monthly and add distilled water (tap water is strictly prohibited) if insufficient. For lithium-ion batteries, use professional equipment to test the cell voltage balance quarterly to avoid overcharging or over-discharging of single cells.

• Regular Cleaning and Maintenance: Clean the battery terminals monthly and apply petroleum jelly to prevent oxidation. Conduct a comprehensive cleaning of the battery case and heat dissipation holes every six months to ensure good heat dissipation. Increase the cleaning frequency especially in dusty warehouses.

Standard 5: "Two In-Places" for Emergency Handling – Respond Quickly to Reduce Losses

Mastering emergency methods in advance can control risks when they initially occur. Focus on the "two in-places":

• In-Place Fire Handling: If the battery smokes or catches fire during charging, immediately disconnect the main power supply, use dry powder fire extinguishers (Type ABC) or carbon dioxide fire extinguishers to put out the fire. Direct water spraying is strictly prohibited (lithium-ion batteries may intensify reactions when in contact with water). Call 119 and evacuate personnel at the same time.

• In-Place Electric Leakage Handling: If the forklift shell is found to be electrified during charging, immediately turn off the power supply with insulated gloves, check if the battery insulation layer is damaged. Do not use it again until professional electricians confirm safety after maintenance.

Conclusion: Safety Comes from Standards, Details Determine Success or Failure

Whether electric forklift charging is safe depends on human operations. According to fire department data, 85% of domestic electric forklift charging accidents in 2024 were caused by non-standard operations, while the accident rate of enterprises that strictly implement operating standards is almost zero.

Has your enterprise formulated a complete electric forklift charging safety system? What charging problems have you encountered in practical operations? Welcome to leave a comment and share your safety management experience!