Many forklift operators and facility managers understand the non-electrical risks of forklift battery charging. Common hazards include handling the electrolyte, moving batteries, and ensuring adequate ventilation.
However, workers and management personnel should also be aware of electrical hazards. Implement the following electrical safety tips in your forklift battery rooms.
Safely Set Up the Charging Station
One of the top tips for setting up a forklift battery charging station is to ensure adequate electrical service. Owners can calculate their power requirements based on fleet needs, ventilation requirements, and necessary cooling equipment.
Electrical equipment must be installed and maintained according to national and local codes. Ungrounded live equipment can fatally shock a person. Bring in a competent electrician to verify your equipment is adequately grounded.
A power disconnect switch must be located near the equipment. If a grounding conductor is part of the power supply cable, connect it to a grounded switch box or building ground. Otherwise, use a separate grounding conductor equal to or larger than the size recommended by the code or your charger manufacturer owner’s manual.
Wear Proper PPE
Another electrical safety tip for forklift battery rooms is to wear personal protective equipment (PPE) to guard against electric shock. Wear rubber insulating gloves and leather protectors to protect hands and arms; rubber insulating sleeves shield arms and shoulders.
Do not work in damp areas without exercising extreme caution. Stand on a dry, electrical safety rubber mat. The body’s electrical resistance significantly decreases when wet, so be sure to keep your clothing dry.
Charge the Batteries Correctly
Finally, follow proper safety procedures while charging the forklift batteries. Take off any jewelry before charging—the metal can cause shocks or burns if those items come in contact with battery terminals. Also, visually inspect connectors and cables for cracks or breaks.
Workers must prevent sparks, electrical arcs, and open flames from occurring in the charging area. This is because the battery may release colorless, explosive hydrogen fumes even after following proper charging protocol in a ventilated room.
Never extend charging leads without manufacturer approval. Erroneously extending the leads can cause the battery charger to operate incorrectly.
Shut off all power at the disconnect switch or line breaker before examining, adapting, or repairing charging equipment. And remember to disconnect the power to any equipment you leave unattended or out of service.
