Introduction:
Forklifts rely heavily on lead-acid batteries to power their operations, and while these batteries are essential for the efficient functioning of the vehicles, they also pose potential risks. Handling sulfuric acid, explosive hydrogen gas, and the recharging process requires strict adherence to safety precautions. In this article, we’ll delve into crucial safety measures to be observed when dealing with forklift batteries.

Safety Precautions during Battery Charging:
Charging lead-acid batteries involves handling sulfuric acid and the potential formation of explosive hydrogen and oxygen gases. Here are vital safety precautions to consider:

1. Approved Charging Areas:

• Charge batteries only in designated, well-ventilated battery-charging areas.
• Install safety showers and eyewash stations in charging areas for immediate response to emergencies.

1. Protective Gear:

• Wear splash-proof goggles, protective clothing (gloves and aprons), and consider using a face shield when handling sulfuric acid.

1. Storage Conditions:

• Do not store acid in hot locations or direct sunlight, as it may compromise the integrity of the acid.

1. Safe Handling:

• Pour concentrated acid slowly into water, avoiding water addition to acid. This is crucial for safety during battery maintenance.

1. Avoid Spills:

• Take extreme care to prevent spills or splashes, as sulfuric acid can damage clothing, eyes, and skin.
• Use eyewash stations if sulfuric acid solution contacts the eyes.

1. Neutralization and Cleanup:

• Neutralize spilled or splashed sulfuric acid with a baking soda solution and rinse the area with clean water.

Responding to Sulfuric Acid Exposure:

• On Skin Exposure:
• Avoid direct contact and wear chemical-resistant protective clothing.
• Flush the contaminated area with lukewarm water for at least 20-30 minutes and transport the victim to an emergency care facility.
• In Eyes Exposure:
• Avoid direct contact and wear chemical-resistant gloves.
• Flush the contaminated eye(s) with lukewarm water for at least 20-30 minutes and transport the victim to an emergency care facility.

Dangers of Exploding Batteries:

• Hydrogen gas generated during the recharging process can be explosive.
• Keep sparks, flames, and other ignition sources away from the charging area.
• Wear protective eyewear and avoid breaking “live” circuits at the terminals.

Best Practices for Recharging Batteries:

• Check electrolyte levels before recharging, ensuring the battery is not frozen.
• If electrolyte covers the plates, do not add water unless needed after recharging.
• Ventilation is essential during recharging to prevent the buildup of explosive hydrogen gas.

Servicing Batteries: Qualified Personnel Only!

• Inspection of cables, connections, and battery components requires qualified personnel.
• Use proper tools, and avoid contact with both terminals simultaneously.
• Clean terminals, trays, and battery cases with water and baking soda solution to neutralize acid.

Conclusion:
Safety is paramount when dealing with forklift batteries. By following stringent safety precautions during charging, responding promptly to acid exposure, understanding the dangers of explosive gases, and adhering to best practices during recharging and servicing, operators can mitigate risks and ensure a secure working environment. It is crucial to emphasize that battery maintenance tasks outlined in this article should be performed by qualified personnel to prevent accidents and ensure the safe operation of forklifts.