When operating an electric forklift, safety is the core prerequisite. It is essential to cover the entire process, including operator qualifications, equipment inspection, operation standards, environmental adaptation, and emergency response. Below are detailed safety precautions applicable to common work scenarios such as warehouses, logistics centers, and manufacturing industries:
I. Operators: Must Possess Qualifications and Receive Pre-Job Training
Certificate-Based Operation
Operators must complete professional training and obtain an electric forklift operation certificate recognized by the state or industry. Unauthorized operation (including apprentices operating independently without supervision) is strictly prohibited.
Health Status
Before starting work, operators must confirm they have no physical discomfort (such as fatigue, dizziness, or blurred vision). Operation under the influence of alcohol, after taking medications (that affect reaction ability), or when in an unstable mood is strictly forbidden.
Pre-Job Briefing
Before each operation, the task details (such as load weight, route, and stacking height) must be clarified, and on-site risk points (such as ramps, obstacles, and crowded areas) must be understood.
II. Equipment Inspection: Mandatory Before Operation to Eliminate Hidden Dangers
Malfunctions of electric forklifts can directly lead to accidents. Before operation, a item-by-item inspection must be conducted in accordance with the "checklist", with focus on the following parts:
| Inspection Parts | Inspection Content |
|---|---|
| Battery System | Check if the battery power is sufficient (recharging is required when below 20% to avoid damage from undercharging); ensure battery connections are secure and free from corrosion; check if the charging port is sealed and free from water ingress/debris. |
| Brake System | Press the brake pedal to check if the brakes are responsive (no delay or deviation); verify if the parking brake (handbrake) is effective and the forklift does not slide when the handbrake is engaged. |
| Steering System | Turn the steering wheel to check if steering is flexible without jamming or abnormal noise; ensure the steering wheel tires have normal air pressure and no damage or cracks. |
| Lifting System | Start the forklift and test if the fork lifting/tilting functions are normal; check if there is any leakage in the hydraulic oil pipes (oil stains, abnormal noise); inspect if the forks are deformed and the fork tips are free from wear (which affects load-bearing capacity). |
| Safety Devices | Check if the warning lights and horn are functioning properly (to alert surrounding personnel); ensure rearview mirrors are clear and unobstructed; verify if the seatbelt is in good condition (must be fastened for sit-down models). |
| Tires/Chassis | Ensure tires have no bulges or air leaks and the wheel hub bolts are secure; check if the chassis is free from collision deformation and no foreign objects (such as cables or cloth) are wrapped around it. |
If any malfunction is found, the forklift must be stopped immediately for use, and maintenance personnel should be contacted for handling. "Operation with faults" is strictly prohibited.
III. Operation Standards: Strict Compliance to Avoid Misoperation
1. Start-Up and Driving: Prioritize Smoothness and Control Speed
Before Start-Up
Confirm that the forks are at the lowest position (10-15 cm above the ground to avoid scraping the ground), the parking brake is released, and there are no personnel/obstacles around.
Driving Speed
- For flat indoor surfaces: ≤ 5 km/h; for open outdoor surfaces: ≤ 10 km/h.
- When passing through crowded areas, corners, doorways, or ramps, the speed must be reduced to ≤ 3 km/h, and the horn should be sounded for warning (follow the principle of "slow down first, look carefully, then pass").
- Overspeeding, sudden braking, and sharp turns (which may cause loads to topple or the forklift to roll over) are strictly prohibited.
Driving Route
Whenever possible, use the pre-designated "forklift lanes" and avoid occupying pedestrian walkways. When crossing thresholds or railway tracks, pass vertically (oblique crossing may cause jamming). Prolonged driving on soft ground (such as mud or sand) or waterlogged areas (which may cause the forklift to get stuck) is prohibited.
2. Load Handling: No Overloading or Unbalanced Loading, Ensure Stability
Compliance with Load Capacity
Strictly operate in accordance with the "rated load capacity" marked on the forklift nameplate. Overloading (e.g., handling 5-ton loads with a forklift rated for 4 tons) is strictly prohibited. When handling irregular loads (such as long strips or loads with offset centers of gravity), adjust the distance between the forks to center the load's center of gravity, and use strapping for fixation if necessary.
Fork Operation
- When picking up loads, the forks must be fully inserted into the bottom of the pallets, and the distance between the two forks should match the width of the pallets (to prevent pallets from slipping).
- When lifting loads, first slowly lift them to 20-30 cm above the ground, and only start driving after confirming the load is stable. Lifting loads while driving is prohibited (to avoid rollover due to a high center of gravity); loads should only be lifted as needed during stacking/unloading.
Stacking/Unloading
- During stacking, align the loads with the shelves, lower them slowly, and avoid colliding with the shelves. Stacking heights exceeding the forklift's maximum lifting height (or beyond the operator's field of vision, which requires guidance from another person) are prohibited.
- After unloading, the empty forks must be lowered to the lowest position before driving. Lifting empty forks high (which may scrape the ceiling or cables) is prohibited.
3. Special Scenarios: Stay Alert to Risks and Take Additional Protection
Operation on Ramps
- When going uphill: The forklift should be in front and the load behind (to prevent the load from sliding down). Drive at a constant speed and do not shift gears.
- When going downhill: The load should be in front and the forklift behind (to use the load's weight to assist in braking). Coasting in neutral is strictly prohibited (drive with gears engaged and control speed using the brakes).
- Turning or parking on ramps is prohibited. If parking is absolutely necessary, firmly engage the handbrake and block the tires with triangular blocks.
Taboos for Carrying People/Loads
- Carrying people on the forks is strictly prohibited (even for short distances, as there are no protective measures and falling risks are high).
- Handling flammable, explosive, or corrosive materials is prohibited (unless using a modified "explosion-proof electric forklift" equipped with special protective devices).
- Operators are prohibited from extending any part of their body outside the forklift while driving (e.g., extending hands or feet out of the door, which may be scraped by obstacles).
IV. Environmental Safety: Pay Attention to the Surroundings to Avoid Collisions
Pedestrian Avoidance
Always maintain awareness of surrounding personnel, especially in blind spots (such as areas blocked by forks or corners). Reduce speed, sound the horn, and if necessary, stop to confirm safety before proceeding. When encountering pedestrians, take the initiative to stop and yield (follow the "pedestrians first" principle).
Obstacle Handling
If there are temporary obstacles (such as cartons or tools) in the passage, they must be cleared before driving. It is prohibited to encroach on other passages or approach edges (such as gaps between shelves or stairwells) when bypassing obstacles.
Charging Safety
- When charging, the forklift must be parked in a dedicated, well-ventilated charging area free from ignition sources, and kept away from flammable and explosive materials.
- Turn off the forklift power before charging. Operating the forklift while it is charging (to avoid short circuits) is strictly prohibited.
- Hydrogen may be generated during battery charging. Smoking or using open flames in the charging area is strictly prohibited, and good ventilation must be maintained (e.g., turn on exhaust fans).
V. Emergency Response: Respond Correctly to Emergencies
Load Tipping
If a load tilts while driving, stop immediately; do not forcefully continue driving. If the load has not fallen, slowly lower the forks and adjust the load position only when confirming no one is around. If the load has fallen, contact personnel for assistance in cleaning up; do not move it alone (to avoid being crushed or hit).
Forklift Malfunctions
If the forklift suddenly shuts down or the brakes fail while driving, immediately turn on the warning lights and sound the horn to alert surrounding personnel. If the malfunction occurs on a ramp, quickly block the tires with triangular blocks to prevent sliding, then contact maintenance personnel.
Personal Injury
If an accident (such as a collision or fall) causes personal injury, stop operations immediately, call an emergency number (e.g., 120), protect the accident scene, report to the person in charge, and do not move the injured person without authorization (to avoid secondary injury).
VI. Other Precautions
After Operation
Park the forklift in the designated area, lower the forks to the lowest position, firmly engage the handbrake, turn off the power, and clean up debris on the forklift surface. If the forklift will not be used for a long time, recharge it and check the battery status.
Regular Maintenance
Even if no problems are found during daily inspections, regular maintenance must be carried out in accordance with the manufacturer's requirements (e.g., monthly inspection of hydraulic oil, quarterly testing of battery performance) to extend the equipment's service life and reduce the risk of malfunctions.
In short, the core of electric forklift safety is "prevention first" — through qualification management, pre-operation inspections, and standardized operations, risks are eliminated in advance to avoid accidents caused by negligence.
