Forklift battery changing/charging

Scope

Electric forklifts are powered by large lead-acid batteries, which must be routinely charged. Worker safety while changing or charging batteries is reliant upon a safe location and appropriate flushing facilities, lifting aids, fire prevention methods, proper tools, and effective training.

Regulatory citations

• 1910.178(g)(2) — Changing and charging storage batteries

Key definitions

• Combustion: A process of igniting and burning a material or substance.
• Emissions: The discharge of gas, radiation, or other substance.
• Hazard: A condition or situation that if left uncontrolled could cause harm.
• Lead-acid battery: Batteries that contain sulfuric acid, or "electrolytes", that conduct electricity when dissolved in water.

Summary of requirements

• Locate battery charging installations in areas designated for that purpose.
• Provide facilities for:
  • Flushing and neutralizing spilled electrolyte,
  • Fire protection,
  • Protecting charging apparatus from damage by trucks, and
  • Adequate ventilation for dispersal of fumes from gassing batteries.
• Provide a conveyor, overhead hoist, or equivalent material handling equipment for handling batteries.
• Position and secure reinstalled batteries in the truck
• Provide a carboy tilter or siphon for handling electrolyte.
• When charging batteries, pour acid into water; water must not be poured into acid.
• Position trucks and apply the brake before attempting to change or charge batteries.
• Assure that vent caps are functioning and the battery (or compartment) cover is open to dissipate heat.
• Prohibit smoking in the charging area.
• Take precautions to prevent open flames, sparks, or electric arcs in battery charging areas.
• Keep tools and other metallic objects away from the top of uncovered batteries.