Precautions for Replacing Electric Forklift Batteries

I. Safety Preparation (Mandatory)

• Turn off power and remove key
  Always switch off the power and remove the key before replacement to prevent sudden lifting, lowering or movement caused by misoperation.
• Wear protective equipment
  Wear gloves, goggles and insulated shoes to avoid electrolyte corrosion, electric shock and pinching injuries.
• Clear the work area
  Keep the surrounding area free of open flames and flammable materials; ensure the ground is dry and non-slip.
• Use proper matching tools
  Use special spreaders, forklift battery lifting frames and insulated wrenches. Do not lift roughly with ordinary steel wire ropes.

II. Removing the Old Battery

• Disconnect the negative terminal first, then the positive terminal
  This prevents short circuits and sparks caused by the wrench contacting the frame.
• Check battery condition
  If the battery is swollen, leaking, overheated or emitting unusual odors, strictly stop handling and isolate it first.
• Lift smoothly
  Lifting points must be on the special battery lugs. Do not lift by the casing, cables or terminals.
• Avoid tilting
  Lead-acid batteries may leak electrolyte if tilted more than 45°, causing corrosion to the vehicle and ground.
• Do not pull cables forcefully
  Avoid breaking internal wiring harnesses.

III. Installing the New Battery

• Model, voltage and dimensions must match
  Incorrect voltage will damage the controller and motor; improper dimensions will result in unstable mounting.
• Connect the positive terminal first, then the negative terminal
  Reverse the disconnection sequence.
• Tighten terminals securely
  Loose connections cause overheating, terminal burning or even fire.
• Secure the battery firmly
  Lock pressure plates and straps tightly to prevent sliding or collision during travel.
• Check insulation
  Ensure the bottom and sides of the battery do not directly short against the metal frame.
• Special notes for lithium batteries
  Do not impact, puncture or squeeze the BMS module. Align plugs before insertion; never pry or force connections.

IV. Charging and Test Run

• After installation, inspect for short circuits, overheating or unusual odors.
• Use the original matching charger for the first charge; do not mix different chargers.
• Conduct a light-load test run and observe:
• Whether voltage remains stable
• Whether any abnormal alarms occur
• Whether the battery overheats
• Record the battery serial number and replacement date to establish a log.

V. Strict Prohibitions (Critical)

• Do not replace batteries while charging or when the battery is overheated.
• Keep open flames away from batteries, especially lead-acid batteries, which release hydrogen and are explosive.
• Do not short-circuit the positive and negative terminals.
• Do not drop, strike or step on the battery.
• Do not disassemble lithium battery packs without authorization.
• If electrolyte contacts skin or eyes, rinse immediately with plenty of water and seek medical attention.

VI. Disposal of Old Batteries

• Lead-acid batteries are hazardous waste and must be handed over to qualified recyclers; do not discard them randomly.
• Lithium batteries also require professional recycling to prevent fire hazards and environmental pollution.