Forklift Linear Boundary Light

(DC12–80V Wide Voltage)

Also known in the industry: linear warning light, linear safety marker light, ground marking light. It projects a straight line beam to mark the working boundary and reversing warning zone of forklifts.

Specificații cheie

Alimentare electrică: DC 12–80V wide voltage, built-in constant current driver. Compatible with 12V/24V/48V/80V electric forklifts, lithium forklifts, AGV-uri, stackers and aerial work platforms. Reverse polarity protection included. Red wire = positive, black wire = negative.

Sursa de lumina: LED. Optional red / albastru / verde (red and blue are mainstream for factories).

Power rating: Common options 5W /18W /20W /30W.

Protecție la intrare: IP67, rezistent la praf și la apă, suitable for workshops, cold storage and humid warehouses.

Locuințe: Die-cast aluminum alloy for vibration resistance and heat dissipation; acrylic focusing lens for sharp light line.

Durata de viata: Typical 30,000～50,000 hours.

Montare: Stainless steel adjustable bracket, fixed with M8 bolts, angle adjustable.

Aplicații

Project a straight line on the ground to indicate the overall width of the forklift and reversing safety boundary, alerting pedestrians.
Anti-collision warning in low-light warehouses, night operations and AGV collaboration areas.
Can be installed in pairs at the rear / side of forklifts, or installed singly as a reversing limit line.

Ghid de selecție

Short single-lens version: Narrow and thin light line, suitable for small-tonnage forklifts and AGVs.

Long three-lens version: Longer and brighter light line, suitable for large-tonnage internal combustion / lithium forklifts.

Distincţie: Linear straight version vs U-shaped (curved) boundary light and arrow warning light, do not mix them up.

The quality of wide-voltage IC is critical. Low-quality units tend to suffer rapid light decay or burnout at high voltage (72–80V).

Instalare & Cablaj

Direct connection to forklift DC power supply, no extra step-down module required, which is the biggest advantage of the 12–80V wide-voltage model.

Recommended mounting height above ground: 2–3 m, projection distance 2–5 m for clear, non-diffused light line.

Cable routing shall be abrasion-resistant and kept away from oil cylinders and moving chains.

Echipamente compatibile

Heli, Hangcha, Lonking, Tailift and other electric forklifts, AGV-uri, aerial work platforms, loaders and small construction machinery.

Work Instruction (SOP) for Forklift Linear Boundary Light Installation

Aplicabil: DC12–80V wide-voltage LED linear boundary light for ground safety marking at forklift sides or rear. Covers mechanical installation, electrical work, optical commissioning, safety specifications, acceptance and maintenance.

Poziția de montare & Mechanical Requirements
Locația de montare

Standard scheme: Install in pairs at upper left and right rear positions or side overhead guard posts; side mounting on overhead guard uprights is also acceptable. Do NOT install on mast, forks, oil cylinders or other moving components (lifting mast changes light position and causes false warning or lamp damage).

Mounting height: 2.0～3.0 m above ground is recommended. Height below 1.8 m results in too short line; height over 3.2 m causes light diffusion and insufficient brightness.

Projection angle: Tilt the lamp downward to project onto the ground behind or beside the forklift. The starting point of the marking line shall be 0.3～0.8 m away from the outer contour of the forklift body, and line length is 2～5 m as required. Left and right lamps shall be installed symmetrically with consistent angles.

Clearance requirement: Keep away from exhaust pipes, hydraulic hoses, chains and moving parts; shall not block driver’s view, original turn signal lights, brake lights or reverse lights.

Fastening Structure

Use original matched adjustable brackets (oţel / oţel inoxidabil). M6 or M8 bolts are preferred, fitted with flat washers, spring washers and lock nuts. Locking is mandatory due to continuous forklift vibration; ordinary nuts alone are not allowed.

The lamp body is die-cast aluminum. Tighten with proper torque; the lens shall not bear squeezing force. Lock adjusting screws after light angle setting to prevent shifting caused by vibration during travel.

Rezistenta la vibratii: Forklifts endure bumping, start and brake impact. Reinforcing backing plates are required if the mounting sheet metal is thin, to avoid tearing the overhead guard.

Mechanical Protection

The exposed lens shall not face directions prone to impact by goods or pallets. Protective mesh cover can be added if necessary.

IP rating of housing ≥IP67. Arrange mounting seam and cable outlet downward to prevent water ingress along cables.

Electrical Wiring Requirements (Critical for 12–80V Wide-Voltage Model)
Circuitul de alimentare

Alimentare electrică: DC 12～80V, compatible with 24V/48V/72V lithium forklifts. Confirm the lamp is equipped with built-in wide-voltage constant current driver; no external step-down module needed.

Polaritate: Red for positive, black for negative. Reverse polarity protection is integrated, yet reverse connection shall be avoided as sustained reverse connection may damage the driver.

Recommended power tapping: Tap from reverse light circuit (auto-on when reversing), or fit independent rocker switch for permanent on. Direct connection to battery terminal without protection is not recommended.

Protecția circuitului

Fuse for each lamp circuit: ≤5A for single lamp; 5A～10A slow-blow fuse for two lamps shared. Install fuse close to the tapping point.

Cable selection: For oily and vibrating forklift environment, use oil-resistant, flexible multi-strand flame-retardant automotive wire. 0.75 mm² minimum; use 1.0 mm² for cable length over 3 m.

Dirijarea cablurilor: Run harness along frame and overhead guard, protected by abrasion-resistant corrugated tube or braided sleeve. Keep away from high-temperature areas, sharp edges and hydraulic pipelines. Fasten clips at intervals ≤300 mm; leave slight slack, do not pull tight.

Încetarea: Waterproof aviation plug is preferred. If crimped directly, seal with waterproof heat shrink tube; bare copper shall not be exposed. Ordinary adhesive tape is prohibited (fails quickly under oil and moisture).

Test de izolare: Measure insulation resistance to ground after power-off wiring; insulation resistance ≥1 MΩ.

Cerințe EMC (Important for Export & AGV Applications)

The wide-voltage driver shall have good anti-interference performance. Route cables away from forklift controllers, instruments and CAN bus to avoid signal disturbance.

Optical & Light Line Commissioning Requirements
Linear beam: Project a sharp solid line on the ground with clean edge, no obvious stray light, blurred edge or uneven brightness.
Luminozitate: The marking line shall be clearly visible under normal warehouse lighting; meanwhile no glare towards human eyes. Never angle the lamp upward during adjustment.
Symmetry: For paired left-right installation, two boundary lines shall be parallel and aligned with forklift side contour; marking line represents warning boundary and shall not be skewed.
Adaptarea la mediu: High-brightness version is preferred for cold storage and dusty workshops. Red or blue light shall follow site safety regulations (blue boundary light is specified in many factories).
Specificații de siguranță
This lamp is an auxiliary safety warning device. It cannot replace original reverse buzzer, reverse light or turn signal light, and only provides visual boundary reminder.
Do not block original statutory lamps or damage the original protection logic of vehicle wiring.
For internal combustion forklifts: Route cables away from high-temperature exhaust parts; cable temperature rating shall match ambient condition. For lithium forklifts: Do not damage battery pack BMS and high-voltage circuits.
Operation zone: The projected marking is only for pedestrian warning. Do not project onto main aisles or dazzle operators of opposite equipment.
Acceptance Checklist after Installation

Brackets are firm without looseness, locking hardware complete, no moving interference

Harness well fixed, waterproof connectors sealed, no cable damage or extrusion

Power-on test: Normal lighting and no flicker within 12–80V working range

Clear light line at correct position, no glare

Reverse-linked version: Lights on automatically when reverse gear engaged, off when disengaged

Vibration check: Shake frame or run engine at idle; light does not flicker or shift angle

No short circuit or abnormal heating: Continuous operation for 30 min, lamp housing and wiring at normal temperature rise

Cerințe de întreținere
Tighten bracket screws monthly; inspect cable abrasion and aging of waterproof connectors.
Lens cleaning: Wipe with soft cloth. Hard objects are forbidden to scratch the lens (scratches cause light diffusion and failure).
Troubleshooting for flickering / intermittent lighting: Check loose connection and water ingress at connector first, then inspect the driver.